KTM 390 Duke (2015) manual

OWNER'S MANUAL 20 15 390 Duke 2015 COL Art. no. 3213123en[...]

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DEAR KTM CUSTOME R 1 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle . You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment in riding this vehicle. Enter the serial numbers of your vehicle below. C[...]

DEAR KTM CUSTOME R 2 ISO 9001(12 100 6061) According to the international quality managem ent standard ISO 9001, KTM uses quality assurance processe s that lead to the maximum possible quality of the products. Issued by: TÜV Management Service KTM-Sportmotorcy cle AG 5230 Mattighofen, Austria[...]

TABLE OF CONTENTS 3 TABLE OF CONTENTS 1 MEANS OF REPRESENTATION ............................ ............ 7 1.1 Symbols used ............................................. ......... 7 1.2 Formats used....................................................... 7 2 SAFETY ADVICE ..................... ............................ ............. 8 2.1 Use de[...]

TABLE OF CONTENTS 4 6.11.16 Range/riding time menu ................................. 43 6.11.17 Total distance menu ODO ............................... 44 6.11.18 Distance menu 1 TRIP 1 ................................ 44 6.11.19 Distance menu 2 TRIP 2 ................................ 45 6.11.20 Setting kilometers or miles .........................[...]

TABLE OF CONTENTS 5 12 BRAKE SYSTEM ............ ............................ ................... 92 12.1 ABS/ant ilock brake system .................. ................ 92 12.2 Checkin g the brake discs .................................... 93 12.3 Checkin g the brake fluid level of the front brake ... 94 12.4 Adding front brake fluid x ............[...]

TABLE OF CONTENTS 6 21.3 Capacit ies ....................................................... 161 21.3.1 Engine oil ................................................... 161 21.3.2 Coolant ................................... .................... 161 21.3.3 Fuel .............................. ............................ . 161 21.4 Chassis ............[...]

1 MEANS OF REPRESEN TATION 7 1.1 Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). All work marked with this symbol requires specialist knowledge and technic al understanding. In the interest of yo[...]

2 SAFETY ADVICE 8 2.1 Use defi nition KTM sport motorcycles are designed and constructe d to meet the normal demands of regular road operation but not for use on race courses or offroad. Info The motorcycle is authorized for public road traffic in the homologous version only. 2.2 Safety a dvice A number of safety instructions need to be followed to[...]

2 SAFETY ADVICE 9 2.3 Degrees of risk and symbols Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measur es are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Identifies a danger t[...]

2 SAFETY ADVICE 10 1 Remov al or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases . 2 Remov al or puncturing of parts of the intake system. 3 Lack of proper maintena nce. 4 Replac ing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified [...]

2 SAFETY ADVICE 11 2.6 Protective clothing Warning Risk of injury   Missing or poor protective clothing present s an increased safety risk. – Wear protective clothing (helmet, boots, glove s, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requireme[...]

2 SAFETY ADVICE 12 2.9 Owner's M anual It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains use- ful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to customize the vehicle ideally for y[...]

3 IMPORTA NT INFORMATIO N 13 3.1 Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM de aler.net ; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resultin[...]

3 IMPORTA NT INFORMATIO N 14 Use of the vehicle under difficult conditions, such in rain, high heat or with a heavy load, can lead to considerably more rapid wear of components such as the drive train, brake system, or suspension compone nts. For this reason, it may be necessary to inspect or replace parts before the next scheduled service. It is i[...]

15[...]

4 VIEW OF VEHICLE 16 4.1 View of vehicle, front left (example) 101923-10[...]

4 VIEW OF VEHICLE 17 1 Combination instrument 2 Rear mirror 3 Clutch lever ( p. 22) 4 Seat 5 Passenger seat 6 Seat lock ( p. 50) 7 Grab handles ( p. 51) 8 Engine number ( p. 21) 9 Side stand ( p. 54) 10 Shift lever ( p. 52)[...]

4 VIEW OF VEHICLE 18 4.2 View of vehicle, rear right (example) 101924-10[...]

4 VIEW OF VEHICLE 19 1 Tool set ( p. 51) 2 Light switch ( p. 24) 2 High beam flasher button ( p. 24) 2 Turn signal switch ( p. 25) 2 Horn button ( p. 23) 3 Ignition/steering lock ( p. 26) 4 Emergency OFF switch ( p. 25) 5 Throttle grip ( p. 23) 6 Hand brake lever ( p. 22) 7 Electric starter button ( p. 26) 8 Chassis number ( p. 20) 8 Type label ( p[...]

5 SERIAL NUMBE RS 20 5.1 Chassis number 101877-10 The chassis number 1 is stamped on the right of the steering head. 5.2 Type lab el 101877-11 The type label 1 is on the right of the frame behind the steering head.[...]

5 SERIAL NUMBE RS 21 5.3 Engine n umber 101876-10 The engine number 1 is stamped on the left side of the engine under the engine sprocket. 5.4 Key num ber B00755-10 The key number 1 can be found on the KEYCODECARD . Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place.[...]

6 CONTROL S 22 6.1 Clutch le ver 101878-10 The clutch lever 1 is fitted on the left side of the handlebar. 6.2 Hand bra ke leve r 101879-10 The hand brake lever 1 is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever.[...]

6 CONTROL S 23 6.3 Throttle grip 101880-10 The throttle grip 1 is fitted on the right side of the handlebar. 6.4 Horn button B00706-11 The horn button 1 is fitted on the left side of the handlebar. Possible states • Horn button in neutral position • Horn button pressed – The horn is operated in this position.[...]

6 CONTROL S 24 6.5 Light switch B00704-10 The light switch 1 is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is turned downward. In this position, the low beam and tail light are switched on. High beam on – Light switch is turned upward. In this position, the high beam and the tail light are switched on. [...]

6 CONTROL S 25 6.7 Turn signal switch B00706-10 The turn signal switch 1 is fitted on the left side of the handlebar. Possible states Turn signal off Turn signal, left, on – Turn signal switch pressed to the left. The turn signal switch returns automatically to the central position after use. Turn signal, right, on – Turn signal switch pressed [...]

6 CONTROL S 26 6.9 Electric starter button B00708-10 The electric starter button 1 is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position • Electric starter button pressed – In this position, the electric starter is actuated. 6.10 Ignition/steerin g lock B00709-01 The ignition/steering lock i[...]

6 CONTROL S 27 6.11 Combination instrument 6.11.1 Overview 401685-10 1 Display ( p. 34) 2 Function buttons ( p. 32) 3 Info display ( p. 38) 4 Indicator lamps ( p. 33)[...]

6 CONTROL S 28 6.11.2 Activation and test 401686-01 Activation The combination instrument is activated when the ignition is switched on. Test The segments of the tachometer and the gear display light up and switch off in sequence. The speed display counts from 0 to 199 and back. The remaining display segments outside the info display light up brief[...]

6 CONTROL S 29 6.11.3 Warning notes 401309-01 Low Oi l Press ure appears on the info display if the oil pressure is too low. 401310-01 Low Fu el Lev el appears on the info display if the fuel level reaches the reserve mark.[...]

6 CONTROL S 30 401311-01 High Co olant Temperature appears on the info display if the coolant temperature rises above the specified value. Coolant temperature 125 °C (257 °F) 401312-01 Side St and Do wn appears on the info display if the side stand is folded down. 401313-01 Low Ba ttery appears on the info display if the battery voltage falls bel[...]

6 CONTROL S 31 401461-01 Service Not Reset appears on the info display for 10 seconds when the ignition is switched on and the distance interval between service appointment s has been exceeded or the service interval display was not reset during a service appointment.[...]

6 CONTROL S 32 6.11.4 Function buttons 401685-12 You can change the display mode with the MODE button 1 . Possible display modes are total distance traveled ( TRIP 1 ), distance 1 ( ODO ) and distance 2 ( TRIP 2 ). Pressing and holding the SET button 2 resets the distance 1 ( TRIP 1 ) and distance 2 ( TRIP 2 ) functions to 0.0 and briefly pressing [...]

6 CONTROL S 33 6.11.5 Indicator lamps 401686-01 Possible states The turn signal indicator light flashes green simultaneous ly with the turn signal – The turn signal is switched on. The engine diagnosis warning lamp ( MIL ) lights up red – The OBD (on- board diagnosis) has detected an emission- or safety-criti cal error. The shift warning lights[...]

6 CONTROL S 34 6.11.6 Display 401685-11 The speed 1 is shown in kilometers per hour km/h or in miles per hour mph . The tachometer 2 shows the engine speed in revolutions per minute. The gear display 3 shows the engaged gear. The coolant temperature appears in segment 4 . The time appears in segment 5 . The filling level in the fuel tank is displac[...]

6 CONTROL S 35 6.11.7 Filling level display in fuel tank 401292-01 The filling level display consists of 9 bars. The more bars are lit, the more fuel is in the fuel tank.[...]

6 CONTROL S 36 6.11.8 TRIP F display 401293-01 If the fuel level drops to the reserve mark, the display mode automatically changes to TRIP F and starts to count from 0.0 , regardless of the previous display mode. Info At the same time as the display mode TRIP F , the general warning lamp lights up and the warning note Low Fu el Lev el appears on th[...]

6 CONTROL S 37 6.11.9 Coolant temperature indicator 401292-01 The temperature display consists of 13 bars. The more bars that light up, the hotter the coolant. When all bars light up, the following warning note appears on the info display: High Co olant Temperature . Possible states • Engine cold – Up to three bars light up. • Engine warm –[...]

6 CONTROL S 38 6.11.10 Info display 401291-10 Various warning notes appear on info display 1 . If the general warning lamp lights up, the corresponding warning note is shown on the info display.[...]

6 CONTROL S 39 6.11.11 Riding time/average speed menu 401334-01 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. The riding time and average speed are displayed [...]

6 CONTROL S 40 Info The average fuel consumption 1 is displayed after several 100 meters of travel after the ignition is switched on. If the ignition was switched off for over 60 minutes, the display of the average speed and average fuel consumption 1 is reset to 0. Press the SET button briefly. Next display mode on the info display 6.11.13 Average[...]

6 CONTROL S 41 6.11.14 Average fuel consumption 2/service menu 401467-01 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. The average fuel consumption 2 in km/L [...]

6 CONTROL S 42 6.11.15 Service/range menu 401468-01 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. This menu shows the distance to the next service and the ran[...]

6 CONTROL S 43 6.11.16 Range/riding time menu 401469-01 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the SET button briefly and repeatedly until the desired info display appears. The range and the riding time are displayed in this menu[...]

6 CONTROL S 44 6.11.17 Total distance menu ODO 401303-01 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the MODE button briefly and repeatedly until ODO appears on the display. ODO shows the total distance covered. Info This value is ret[...]

6 CONTROL S 45 Press the SET button for 5 - 10 seconds. Display of TRIP 1 is reset Press the MODE but- ton. Next display mode on the display 6.11.19 Distance menu 2 TRIP 2 401305-01 Condition Alternative 1 • The ignition is on. • The motorcycle is stationary. Alternative 2 • The ignition is on. • The motorcycle is moving. – Press the MODE[...]

6 CONTROL S 46 The motorcycle is stationary. 401303-01 – Press the MODE button briefly and repeatedly until ODO appears on the display. – Press the MODE button for 5 - 10 seconds. The display changes from km/h to mph or from mph to km/h . 6.11.21 Setting the time Condition The ignition is on. The motorcycle is stationary. 401303-01 – Press th[...]

6 CONTROL S 47 6.11.22 Adjusting the shift speed RPM 1 Condition The ignition is on. The motorcycle is stationary. 401307-01 – Press the MODE button briefly and repeatedly until TRIP 2 appears on the display. – Press the MODE button for 5 - 10 seconds. The display RPM 1 appears. Info The engine speed can be set at intervals of 50. RPM 1 is the [...]

6 CONTROL S 48 401308-01 – Press the MODE button briefly and repeatedly until TRIP 2 appears on the display. – Press the SET button for 5 - 10 seconds. The display RPM 2 appears. Info The engine speed can be set at intervals of 50. RPM 2 is the engine speed above which the shift warning light lights up con- stantly. The speed RPM 2 must alway s[...]

6 CONTROL S 49 Warning Danger of poisoning   Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immedia tely clean contaminated areas on the skin with soap and water. I[...]

6 CONTROL S 50 6.13 Closing the filler cap B00711-01 Warning Fire ha zard   Fuel is highly flammable, poisono us and harmful to your health. – After closing the filler cap, ensure that it is locked properly. Change cloth- ing that has been contaminated with fuel. Immediately clean contami nated areas on the skin with soap and water. – Close t[...]

6 CONTROL S 51 6.15 Tool set B00758-10 The tool set 1 is located under the passenger seat. 6.16 Grab handles 101882-10 The grab handles 1 are used for moving the motorcycle around. If you carry a passenger, the passenger can hold onto the grab handles during the trip.[...]

6 CONTROL S 52 6.17 Passenger footrests B00713-01 The passenger footrests can be folded in and out. Possible states • Passenger footrests folded up – For operation without a passenger. • Passenger footrests folded down – For operation with a passenger. 6.18 Shift lever 101885-11 Shift lever 1 is mounted on the left side of the engine.[...]

6 CONTROL S 53 101885-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 6.19 Foot brake lever 101883-10 Foot brake lever 1 is located in front of the right footrest. The foot brake lever is used to activate the rear brake.[...]

6 CONTROL S 54 6.20 Side stand 101884-10 The side stand 1 is on the left side of the vehicle. The side stand is used to park the motorcycle. Info The side stand must be folded up during motorcycle use. Side stand is coupled with the safety start system; see the riding instructions. Possible states • Side stand folded out – The vehicle can be le[...]

7 PREPARIN G FOR USE 55 7.1 Advice on first use Danger Danger of accidents   Danger arising from the rider's judgem ent being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired. Warning Risk of injury   Missing or poor protective clothing present s[...]

7 PREPARIN G FOR USE 56 – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover. – Before your first trip, read the entire operating instructions carefully. – Get to know the controls. – Get used to handling the motorc[...]

7 PREPARIN G FOR USE 57 7.3 Loading the vehicle Warning Danger of accidents   Unstabl e handling characteristics. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle oper ational and with a full tank, driver and passenger with protective clothing and helmet, baggage . Warning Danger of acciden[...]

7 PREPARIN G FOR USE 58 – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu- tion between the front and rear wheels. – Do not exceed the overall maximum permitted weight and the axle loads. Guideline Maximum permissible overal l weight 335 kg (739 lb.) Maximu[...]

8 RIDING INSTRUC TIONS 59 8.1 Checks and maintenance when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is roadworthy. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p. 143) – Check the brake fluid level of the front brake. ( p. 94) – Check the re[...]

8 RIDING INSTRUC TIONS 60 8.2 Starting Danger Danger of poisoning   Exhaust gase s are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system . Caution D[...]

8 RIDING INSTRUC TIONS 61 B00782-10 – Sit on the vehicle, take the weight off of the side stand, and move up all the way. – Turn the emergency OFF switch to the position . – Switch on the ignition by turning the ignition key to the position . After you switch on the ignition, you can hear the fuel pump working for about two seconds. The funct[...]

8 RIDING INSTRUC TIONS 62 401685-15 Switching off ABS KTM recommends riding with ABS at all times. However, situations may arise in which ABS is not advantageous. Condition Vehicle stationary, engine running. – Press the 1 button for 3 – 5 seconds. The ABS warning lamp starts flashing; ABS is deactivated. 8.3 Starting off – Pull the clutch le[...]

8 RIDING INSTRUC TIONS 63 Warning Danger of accidents   Malfunc tions caused by incorrect ignition key position. – Do not change the ignition key position during a journey. Warning Danger of accidents   Distracti on from traffic activity by adjustments to the vehicle. – Make all adjustments when the vehicle is at a standstill. Warning Risk [...]

8 RIDING INSTRUC TIONS 64 Warning Danger of accidents   Unstabl e handling characteristics due to slipped baggage. – Check the way your baggage is fixed regularly. Warning Danger of accidents   Lack of roadworthin ess. – After a fall, check the vehicle as usual before preparing for use. Note Engine failure   Overheating of engine. – If [...]

8 RIDING INSTRUC TIONS 65 – Accelerate only up to a speed suitable for the road surface and weather conditions. Par- ticularly in bends, do not shift, and accelerate very carefully. – To shift down, brake if necessary and close the throttle at the same time. – Pull the clutch lever and shift into a lower gear, release the clutch lever slowly [...]

8 RIDING INSTRUC TIONS 66 Warning Danger of accidents   Delayed brake actio n on salted roads. – There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the deposits from the discs by carefully applying the brakes. Warning Danger of accidents   Greater stoppi ng distance due to[...]

8 RIDING INSTRUC TIONS 67 8.6 Stopping, parking Warning Risk of misappropriation   Us age by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons . If you leave the vehicle, lock the steering and remove the ignition key. Warning Danger of burns   Some vehicle compo[...]

8 RIDING INSTRUC TIONS 68 – Switch off the ignition by turning the ignition key to the position . Info If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock, power continues to flow to most power consumers and the battery will discharge. You should therefore always switch off the eng[...]

8 RIDING INSTRUC TIONS 69 401448-01 – Switch off the engine and remove the ignition key. – Use tension belts or other suitable devices to secure the motorcycle against accidents or falling over. 8.8 Refueling Danger Fire ha zard   Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch [...]

8 RIDING INSTRUC TIONS 70 – Only refuel with clean fuel that meets the specified standards. Warning Environmental hazard   Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. B00719-10 – Switch off the engine. – Open the filler cap. ( p. 48) – Fill[...]

9 SERVICE SCHED ULE 71 9.1 Service schedule Every 15,000 km (9,321 mi) o r every 2 years Every 7,500 km (4 ,660 m i) or annually Once after 1,000 km (621.4 m i) Check the functioning of the electrical equipment. ○ ● ● Read out the fault memory using the KTM diagnostics tool. x ○ ● ● Change the engine oil and oil filter, clean the oil sc[...]

9 SERVICE SCHED ULE 72 Every 15,000 km (9,321 mi) o r every 2 years Every 7,500 km (4 ,660 m i) or annually Once after 1,000 km (621.4 m i) Check the valve clearance. x ○ ● Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and bellows for cracking, leaks, and correct routing . x ○ ● ● Check the antifreeze and coolant level. ( [...]

10 TUNING THE CHASSIS 73 10.1 Adjusting the spring preload of the shock absorber x Warning Danger of accidents   Modifica tions to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications , ride slowly at first to get the feel of the new ride behavior. Info The spring preload defines the initial si[...]

10 TUNING THE CHASSIS 74 10.2 Adjusting the shift lever Info The adjustment range of the shift lever is limited. 101927-10 – Loosen nuts 1 . – Adjust the shift lever by turning shift rod 2 . Guideline Shift rod adjustment range A 110… 122 mm (4.33… 4.8 in) Info Make the same adjustments on both sides. At least five screw threads must be scr[...]

11 SERVICE WORK ON THE CHASSIS 75 11.1 Raising the motorcycle with the rear wheel stand Note Danger of damage   The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. B01387-01 – Mount the support of the wheel stand. – Insert the adapter in the rear wheel stand. Adapter (61029055130) Rear wheel[...]

11 SERVICE WORK ON THE CHASSIS 76 101884-10 – Secure the motorcycle against falling over. – Remove the rear wheel stand and lean the vehicle on the side stand 1 . – Remove the support of the wheel stand. 11.3 Raising the motorcycle with the front wheel stand Note Danger of damage   The parked vehicle may roll away or fall over. – Always p[...]

11 SERVICE WORK ON THE CHASSIS 77 101888-01 – Move the handlebar to the straight-ahead position. Attach the lifting gear to the steering stem. Adapter (61029955620) Front wheel stand (61029055500) Info Always raise the rear of the motorcycle first. – Raise the front of the motorcycle. 11.4 Taking the motorcycle off of the front wheel stand Note[...]

11 SERVICE WORK ON THE CHASSIS 78 101887-10 – Mount cap 1 . 11.5 Removing the passenger seat 101881-10 – Insert the ignition key in seat lock 1 and turn it clockwise. – Raise the rear of the seat, push it towards the rear, and remove it upwards. – Remove the ignition key from the seat lock.[...]

11 SERVICE WORK ON THE CHASSIS 79 11.6 Mounting the passenger seat 101890-10 – Attach hooks 1 on the passenger seat to brackets 2 on the subframe, and lower it at the rear while pushing forward. – Press down the passenger seat until it clicks into place. Warning Danger of accidents   The passenge r seat can come loose from the anchoring if it[...]

11 SERVICE WORK ON THE CHASSIS 80 11.8 Mounting the seat 101892-10 Main work – Attach seat recesses A at screws 1 and lower at the rear. – Mount and tighten screws 2 . Guideline Screw, seat M6 11 Nm (8.1 lbf ft) Finishing work – Mount the passenger seat. ( p. 79)[...]

11 SERVICE WORK ON THE CHASSIS 81 11.9 Checking for chain dirt accumulation 400678-01 – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 81) 11.10 Cleaning the chain Warning Danger of accidents   Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleanin[...]

11 SERVICE WORK ON THE CHASSIS 82 Info The service life of the chain depends largely on its maintenance. 400725-01 – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( p. 172) – After drying, apply chain spray. Chain lube for road use ( p. 172) 11.11 Ch[...]

11 SERVICE WORK ON THE CHASSIS 83 B00731-10 – Lean the motorcycle on the side stand. – Shift gear to neutral. – In the area of chain sliding guard, press the chain upward toward the swingarm and determine chain tension A . Info The upper chain section B must be taut. Chain wear is not always even, so you should repeat this measurement at diff[...]

11 SERVICE WORK ON THE CHASSIS 84 11.12 Adjusting the chain tension Warning Danger of accidents   Danger cause d by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket , bearings in the transmission and in the rear wheel) will be under additional load. In[...]

11 SERVICE WORK ON THE CHASSIS 85 101893-10 Main work – Loosen nut 1 . – Loosen nuts 2 . – Adjust the chain tension by turning adjusting screws 3 on the left and right. Guideline Chain tension 5… 7 mm (0.2… 0.28 in) Turn adjusting screws 3 on the left and right so that the markings on the left and right chain adjuster 4 are in the same po[...]

11 SERVICE WORK ON THE CHASSIS 86 11.13 Checking the chain, rear sprocket, and engine sprocket 100132-10 – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket and engine sprocket are worn: – Change the power set. x Info The engine sprocket, rear sprocket, and chain should always be replaced together.[...]

11 SERVICE WORK ON THE CHASSIS 87 1 2 3 1 8 1 9 20 0 0 0 B B 0 0 A A 401288-10 – Shift gear to neutral. – Pull the lower chain section with specified weight A . Guideline Weight, chain wear measurement 15 kg (33 lb.) – Measure the distance B of 20 chain links in the lower chain section. Info Chain wear is not always even, so you should repeat[...]

11 SERVICE WORK ON THE CHASSIS 88 B01416-10 – Remove screws 2 and 3 and release screw 1 . Push the chain guard aside. C00199-10 – Check the chain sliding guard for wear. » If drill hole D becomes visible on the chain sliding guard in area C : – Change the chain sliding guard. x – Check that the chain sliding guard is firmly seated. » If t[...]

11 SERVICE WORK ON THE CHASSIS 89 B01416-10 – Position the chain guard and tighten screw 1 . Guideline Screw, chain guard EJOT PT ® 4 Nm (3 lbf ft) – Tighten screw 2 . Guideline Screw, chain guard EJOT PT ® 4 Nm (3 lbf ft) – Tighten screw 3 . Guideline Remaining screws, chassis M5 5 Nm (3.7 lbf ft)[...]

11 SERVICE WORK ON THE CHASSIS 90 11.14 Removing the front spoiler 101895-10 – Remove screws 1 . 101896-10 – Remove screws 2 . – Take off the front spoiler.[...]

11 SERVICE WORK ON THE CHASSIS 91 11.15 Fitting front spoiler 101895-10 – Position the front spoiler. Mount screws 1 but do not tighten yet. 101896-10 – Mount and tighten screws 2 . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) – Tighten screw 1 . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft)[...]

12 BRAKE SYSTEM 92 12.1 ABS/antilock brake system 401687-10 The ABS unit 1 , which consists of a hydraulic unit, ABS control unit, and return pump, is installed under the seat. A wheel speed sensor 2 is located at the front and rear wheels. Warning Danger of accidents   Function al limitations of the ABS – The rear wheel may only be spun with t[...]

12 BRAKE SYSTEM 93 The ABS warning lamp 3 must light up briefly after the ignition is switched on and should then go out after starting off. If it does not go out after starting off or if it lights up while riding, this indicates a fault in the ABS system. In this case, the ABS is no longer enabled and the wheels may lock during braking. The brake [...]

12 BRAKE SYSTEM 94 – Change the brake discs. x – Check the front and rear brake discs for damage, cracking, and deformation. » If the brake disc shows signs of damage, cracking, or deformation: – Change the brake discs. x 12.3 Checking the brake fluid level of the front brake Warning Danger of accidents   Failure of the brake system. – I[...]

12 BRAKE SYSTEM 95 12.4 Adding front brake fluid x Warning Danger of accidents   Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning[...]

12 BRAKE SYSTEM 96 C00201-10 – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws 1 . – Remove cover 2 with membrane 3 . – Add brake fluid to level A . Guideline Level A 5 mm (0.2 in) Brake fluid DOT 4 / DOT 5.1 ( p. 169) – Position the cover with the membrane. Mount and tighten the screws. I[...]

12 BRAKE SYSTEM 97 B00739-10 – Check the brake linings for minimum thickness A . Minimum thickness A ≥ 1 mm ( ≥ 0.04 in) » If the minimum thickness is less than specified: – Change the front brake linings. x – Check the brake linings for damage and cracking. » If there is wear or tearing: – Change the front brake linings. x 12.6 Check[...]

12 BRAKE SYSTEM 98 101897-10 – Disconnect spring 1 . – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel A . Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) » If the free travel does not meet specifications: – Adjust the free travel of th[...]

12 BRAKE SYSTEM 99 101897-11 – Disconnect spring 1 . – Release nut 2 and use screw 3 to adjust the specified free travel A . Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) Info The range of adjustment is limited. – Hold screw 3 and tighten nut 2 . – Attach spring 1 . 12.8 Checking the rear brake fluid level Warning Dan[...]

12 BRAKE SYSTEM 100 Warning Danger of accidents   Reduced brak ing efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) 101898-10 – Stand the vehicle upright. – Check the brake fluid level in the brake fluid reservoir. [...]

12 BRAKE SYSTEM 101 Warning Danger of accidents   Reduced brak ing efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard   Hazardous substances caus e environmental damage. – Oil, grease, fil[...]

12 BRAKE SYSTEM 102 12.10 Checking the rear brake linings Warning Danger of accidents   Reduced brak ing efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your author ized KTM workshop will be glad to help.) Note Danger of accidents   Reduced brak ing efficiency caused by damaged brake discs. – If the brake [...]

13 WHEELS, TIRES 103 13.1 Removing the front wheel x Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 75) – Raise the motorcycle with the front wheel stand. ( p. 76) B01391-10 Main work – Remove screws 1 and push the fender to the side. – Remove screw 2 and pull wheel speed sensor 3 out of the hole. – Loosen screws [...]

13 WHEELS, TIRES 104 13.2 Installing the front wheel x Warning Danger of accidents   Reduced brak ing efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. B01392-10 Main work – Check the wheel bearing for damage and wear. » If the wheel bea[...]

13 WHEELS, TIRES 105 B01391-11 – Clean the thread of the wheel spindle and screw 2 . – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw 2 . Guideline Screw, front wheel spindle M8 30 Nm (22.1 lbf ft) – Insert wheel speed sensor 3 into the hole. Mount and tighten scr[...]

13 WHEELS, TIRES 106 101900-10 – Remove nut 3 and the washer. Remove chain adjuster 4 . – Holding the rear wheel, withdraw wheel spindle 54 with the washer and chain adjuster. – Push the rear wheel forward as far as possible and take the chain off the rear sprocket. Warning Danger of accidents   Reduced brak ing effect caused by damaged bra[...]

13 WHEELS, TIRES 107 Warning Danger of accidents   No braking effect when operatin g the rear brake. – After installing the rear wheel, always operate the foot brake until the pressure point is reached. Main work – Check the rear hub rubber dampers. x ( p. 108) 101901-10 – Check the wheel bearing for damage and wear. » If the wheel bearing[...]

13 WHEELS, TIRES 108 101900-11 – Pull the rear wheel back and mount wheel spindle 3 with the washer and chain adjuster 4 . Info Mount the left and right chain adjusters 4 in the same position. – Mount nut 2 and washer. – Push the rear wheel forward so that the chain adjusters are on the screws, and tighten nut 2 . Guideline In order for the r[...]

13 WHEELS, TIRES 109 Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 75) – Remove the rear wheel. x ( p. 105) 101925-10 Main work – Check bearing 1 . » If the bearing is damaged or worn: – Change the bearing. x – Check the rubber dampers 2 of the rear hub for damage and wear. » If the rubber dampers of the rear h[...]

13 WHEELS, TIRES 110 13.6 Checking the tire condition Warning Danger of accidents   Uncontr ollable vehicle handling in the event of a flat tire. – In the interest of safety, replace damaged or worn tires immediately. (Your authorized KTM worksho p will be glad to help.) Warning Danger of crashing   Poor vehicle handlin g due to different tir[...]

13 WHEELS, TIRES 111 » If the tread depth is less than the minimum permissible depth: – Change the tires. – Check the age of the tires. Info The tire's date of the manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking. The first two digits refer to the week of manufacture and last two[...]

13 WHEELS, TIRES 112 » If the tire air pressure does not meet specifications: – Correct the tire air pressure. – Mount the dust cap.[...]

14 ELECTRIC AL SYSTEM 113 14.1 Removing the battery x Warning Risk of injury   Battery acid and battery gases cause serious chemica l burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles . – Avoid contact with battery acid and battery gases. – Keep sparks and open flames away from the batte[...]

14 ELECTRIC AL SYSTEM 114 101904-10 – Pull back the positive terminal cover 3 . – Disconnect the positive cable 4 of the battery. – Detach rubber band 5 . – Pull the battery up and out of the battery holder. Info Never operate the motorcycle with a discharged battery or without a battery. In both cases, electrical components and safety devi[...]

14 ELECTRIC AL SYSTEM 115 101903-11 – Connect the negative cable 4 of the battery. – Position the negative terminal cover 5 . Finishing work – Mount the seat. ( p. 80) – Mount the passenger seat. ( p. 79) – Set the clock. ( p. 46) 14.3 Recharging the battery x Warning Risk of injury   Battery acid and battery gases cause serious chemica[...]

14 ELECTRIC AL SYSTEM 116 Warning Environmental hazard   The battery contains elements that are harmful to the environment. – Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentall y compatible manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batt[...]

14 ELECTRIC AL SYSTEM 117 B01395-10 Main work – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000 ) You can also use the battery charger to test rest potential and start potential of the bat- tery, and to test the alternator. With this device, you cannot overcharge the battery. Info Never remo[...]

14 ELECTRIC AL SYSTEM 118 14.4 Changing the ABS fuses Warning Fire ha zard   The electrical system can be overloade d if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info Two fuses for the ABS are located under the passenger seat. These fuses protect the return pump and the hydraulic un[...]

14 ELECTRIC AL SYSTEM 119 Tip Replace spare fuse B in the fuse box so that it is available if needed. – Mount the protection cap. 101905-11 To cha nge th e fuse of the ABS return pump: – Take off the protection cap and remove fuse 2 . Warning Fire ha zard   The electrical system can be overloaded if the wrong fuses are used. – Use only fuse[...]

14 ELECTRIC AL SYSTEM 120 Preparatory work – Switch off all power consumers and switch off the engine. – Remove the passenger seat. ( p. 78) B01410-01 Main work – Open fuse box cover. – Remove the defective fuse. Guideline Fuse 1 - 30 A - main fuse Fuse 2 - 15 A - start auxiliary relay, alarm system (OPTIONAL) Fuse 3 - 15 A - control unit, [...]

14 ELECTRIC AL SYSTEM 121 Fuse (75011088010) ( p. 163) Fuse (75011088015) ( p. 163) Fuse (75011088030) ( p. 163) Tip Replace the spare fuse in the fuse box so that it is available if needed. – Check that the power consumer is functioning properly. – Close the fuse box cover. Finishing work – Mount the passenger seat. ( p. 79) 14.6 Changing th[...]

14 ELECTRIC AL SYSTEM 122 101907-10 Main work – Remove expanding rivets 1 . 101908-10 – Remove screws 2 . – Lift the headlight mask slightly and swing forward. B00760-10 – Take off protection cap 3 . – Disconnect plug-in connector 4 .[...]

14 ELECTRIC AL SYSTEM 123 B00761-10 – Detach retaining clamp 5 . – Remove headlight bulb 6 . – Position the new headlight bulb in the headlight housing. Headlight (H4/socket P43t) ( p. 163) Info Insert the headlight bulb so that the catches latch into the recesses. – Attach retaining clamp 5 . B00760-10 – Connect plug-in connection 4 . ?[...]

14 ELECTRIC AL SYSTEM 124 101907-10 – Mount expanding rivets 1 on both sides. – Check that the lighting is functioning properly. 14.7 Changing the parking light bulb Note Damage to reflector   Reduced brigh tness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease[...]

14 ELECTRIC AL SYSTEM 125 308243-10 – Remove screws 2 . – Lift the headlight mask slightly and swing forward. B00762-10 – Remove screws 3 . – Take off cover 4 .[...]

14 ELECTRIC AL SYSTEM 126 B00763-10 – Pull the socket with bulb 5 out of the housing. – Remove the bulb. – Position a new light bulb in the socket. Parking light (W5W/socket W2.1x9. 5d) ( p. 163) – Position the socket with bulb 5 in the housing. B00762-10 – Position cover 4 . – Mount and tighten screws 3 .[...]

14 ELECTRIC AL SYSTEM 127 308243-10 – Fold the headlight mask up. – Mount and tighten screws 2 . Guideline Screw, headlight mask M6 11 Nm (8.1 lbf ft) 101907-10 – Mount expanding rivets 1 on both sides. – Check that the lighting is functioning properly.[...]

14 ELECTRIC AL SYSTEM 128 14.8 Checking the headlight setting 0 0 A A 0 0 B B 400726-10 – Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight. – Make another mark at a distance B under the first mark. Guideline Distance B 5 cm (2 in) – Position the[...]

14 ELECTRIC AL SYSTEM 129 14.9 Adjusting the headlight range 101907-10 Main work – Remove expanding rivets 1 . 101908-10 – Remove screws 2 . – Lift the headlight mask slightly and swing forward.[...]

14 ELECTRIC AL SYSTEM 130 B00764-10 – Adjust the beam distance of the headlight by turning screw 3 . Guideline For a motorcycle with rider, and with luggage and a passenger if applicable, the light/dark boundary must be exactly on the lower mark (applied in: Checking headlight adjustment). Info Turn clockwise to increase the headlight range; turn[...]

14 ELECTRIC AL SYSTEM 131 Finishing work – Check the headlight setting. ( p. 128)[...]

15 COOLING SYSTE M 132 15.1 Cooling system 101909-10 Water pump 1 in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap 2 . Heat expansion causes excess coolant to flow into compensating tank 3 . When the temperature falls, this surplus coolant is sucked back into[...]

15 COOLING SYSTE M 133 101922-10 The coolant is cooled by the air stream and a radiator fan 4 , which is controlled by a ther- moswitch. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect. 15.2 Checking the antifreeze and coolant level Warning Danger of scalding   During motorcy cle operation, the [...]

15 COOLING SYSTE M 134 Warning Danger of poisoning   Coolant is poisonou s and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immedi- ately and contact a physician. Immediately clean contam inated areas on the skin with soap and water. If coolant is swall[...]

15 COOLING SYSTE M 135 101911-10 – Remove radiator cap 2 . – Check the coolant antifreeze. − 25… − 45 °C ( − 13… − 49 °F) » If the coolant antifreeze does not meet specifications: – Correct the coolant antifreeze. – Check the coolant level in the radiator. The radiator must be completely filled. » If the coolant level does n[...]

15 COOLING SYSTE M 136 Warning Danger of poisoning   Coolant is poisonou s and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immedi- ately and contact a physician. Immediately clean contam inated areas on the skin with soap and water. If coolant is swall[...]

15 COOLING SYSTE M 137 Alternative 2 Coolant (mixed ready to use) ( p. 169) » If you had to add more coolant than the specified amount: > 0.20 l (> 0.21 qt.) – Fill/bleed the cooling system. x ( p. 138) – Mount the radiator cap. 15.4 Draining the coolant x Warning Danger of scalding   During motorcy cle operation, the coolant gets very[...]

15 COOLING SYSTE M 138 101912-10 Main work – Stand the motorcycle upright. – Place a suitable container under the engine. – Remove screw 1 . – Remove the radiator cap. – Completely drain the coolant. – Mount screw 1 with a new seal ring and tighten it. Guideline Plug, water pump drain hole M6 8 Nm (5.9 lbf ft) 15.5 Filling/bleedin g the[...]

15 COOLING SYSTE M 139 101913-10 – Open bleeder screw 2 by three turns. – Tilt the vehicle slightly to the right. – Pour in coolant until it emerges without bubbles at the bleeder screw, and then mount and tighten the bleeder screw immediately. Alternative 1 Coolant ( p. 169) Alternative 2 Coolant (mixed ready to use) ( p. 169) – Fill the r[...]

16 TUNING THE ENGINE 140 16.1 Checking the play in the throttle cable 400192-10 – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip backward s and forwards to ascertain the play in the throttle cable. Throttle cable play 3… 5 mm (0.12… 0.2 in) » If the throttle cable p[...]

16 TUNING THE ENGINE 141 16.2 Adjusting the play in the throttle cable x B00728-10 – Move the handlebar to the straight-ahead position. – Push back sleeve 1 . – Loosen lock nut 2 . – Adjust the play in the throttle cable by turning adjusting screw 3 . Guideline Throttle cable play 3… 5 mm (0.12… 0.2 in) – Tighten lock nut 2 . – Slid[...]

16 TUNING THE ENGINE 142 » If the clutch lever play changes: – Check the routing of the clutch cable. 16.4 Adjusting the clutch cable play x 101915-10 – Move the handlebar to the straight-ahead position. – Push back sleeve 1 . – Loosen lock nut 2 . – Adjust the play in the clutch level A by turning adjusting screw 3 . Guideline Clutch le[...]

17 SERVICE WORK ON THE ENGINE 143 17.1 Checking the engine oil level Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. 101916-10 Main work – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level. The engine oil must be b[...]

17 SERVICE WORK ON THE ENGINE 144 Info Drain the engine oil only when the engine is warm. Preparatory work – Remove the front spoiler. ( p. 90) – Stand the motorcycle on its side stand on a horizontal surface. 101917-10 Main work – Place a suitable container under the engine. – Remove the oil drain plug 1 with the O-ring. – Remove oil scr[...]

17 SERVICE WORK ON THE ENGINE 145 101918-10 – Remove screws 5 . Remove the oil filter cover 6 with the O-ring. – Pull oil filter 7 out of the oil filter housing. Circlip pliers reverse (51012011000 ) – Completely drain the engine oil. – Thoroughly clean the parts and sealing area. 101919-10 – Insert oil filter 7 . – Oil the O-ring of th[...]

17 SERVICE WORK ON THE ENGINE 146 101920-10 – Remove the oil filler plug 8 with the O-ring from the clutch cover and fill up with engine oil. Engine oil 1.6 l (1.7 qt.) Engine oil (SAE 15W/50) ( p. 170) – Install and tighten the oil filler plug with the O-ring. Danger Danger of poisoning   Exhaust gase s are toxic and inhaling them may result[...]

17 SERVICE WORK ON THE ENGINE 147 101921-10 Main work – Remove the oil filler plug 1 with the O-ring from the clutch cover and fill up with engine oil. Engine oil (SAE 15W/50) ( p. 170) Info For optimal performance of the engine oil, do not mix different types of engine oil. If appropriate, change the engine oil. – Install and tighten the oil f[...]

18 CLEANING , CARE 148 18.1 Cleaning the motorcycle Note Material damage   Damage and destruction of components by high-pressur e cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connec tors, cables, bearings, etc. Maintain a minimum distance of 60 cm betwee[...]

18 CLEANING , CARE 149 Info Use warm water containing normal motorcycle clean er and a soft sponge. Never apply motorcycle cleaner to a dry vehicle; always rinse the vehicle with water first. If the vehicle was operated in road salt, clean it with cold water. Warm water would enhance the corrosive effects of salt. – After rinsing the motorcycle w[...]

18 CLEANING , CARE 150 Perfect Finish and high gloss polish for paints ( p. 173) Info Do not polish parts that were matte when delivered as this would strongly impair the material quality. – Treat all plastic parts and powder-coated parts with a mild cleaning and care product. Special cleaner for glossy and matte paint finishes, metal and plastic[...]

18 CLEANING , CARE 151 – Treat the engine, swingarm, and all other bright and zinc-plated parts (except for the brake discs) with a wax-based corrosion inhibitor. Info Corrosion inhibitor is not permitted to come in contact with the brake discs as this would greatly reduce the braking force. – Clean the chain. ( p. 81)[...]

19 STORAGE 152 19.1 Storage Info If you want to garage the motorcycle for a longer period, take the following steps. Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessa ry, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop[...]

19 STORAGE 153 – Raise the motorcycle with the rear wheel stand. ( p. 75) – Raise the motorcycle with the front wheel stand. ( p. 76) – Cover the motorcycle with a tarp or similar cover that is permeable to air. Info Do not use non-porous materials since they prevent humidity from escaping , thus causing corrosion. Avoid running the engine fo[...]

20 TROUBLE SHOOTING 154 Faults Possible cause Actio n Engine does not crank when the elec- tric starter button is pressed Operating error – Go through the steps of starting the engine. ( p. 60) Battery discharged – Recharge the battery. x ( p. 115) Fuse 1 , 3 , 4 , or 8 is blown – Change the fuses of individual power consumers. ( p. 119) No g[...]

20 TROUBLE SHOOTING 155 Faults Possible cause Actio n Engine overheats Defect in radiator fan system – Check the radiator fan system. x The engine diagnosis warning lamp ( MIL ) lights up red Defect in fuel injection system – Read out the fault memory using the KTM diag- nostics tool. x Engine dies during the trip Lack of fuel – Refuel. ( p. [...]

20 TROUBLE SHOOTING 156 Faults Possible cause Actio n Battery discharged Battery is not being charged by alter- nator – Check the charging voltage. x – Check the open-circuit current. x Combination instrument show s nothing on the display Fuse 8 blown – Change the fuses of individual power consumers. ( p. 119) – Set the clock. ( p. 46) Spee[...]

21 TECHNICA L DATA 157 21.1 Engine Design 1-cylinder 4-stroke engine, water-co oled Displacement 375 cm³ (22.88 cu in) Stroke 60 mm (2.36 in) Bore 89 mm (3.5 in) Compression ratio 12.8:1 Control DOHC, 4 valves controlled via cam lever, chain drive Valve diameter, intake 36 mm (1.42 in) Valve diameter, exhaust 29 mm (1.14 in) Valve clearance, intak[...]

21 TECHNICA L DATA 158 4th gear 21:24 5th gear 23:22 6th gear 25:21 Mixture preparation Electronically controlled fuel inject ion Ignition Contactless controlled fully electro nic ignition with digital ignition adjustment Alternator 12 V, 238 W Spark plug BOSCH VR 5 NE Spark plug electrode gap 0.8 mm (0.031 in) Spark plug BOSCH VR 5 NEU Spark plug [...]

21 TECHNICA L DATA 159 Nut, water pump impeller M6 10 Nm (7.4 lbf ft) Loc tite ® 243™ Oil nozzle M6 6 Nm (4.4 lbf ft) Loctite ® 243™ Plug, water pump drain hole M6 8 Nm (5.9 lbf ft) – Screw, alternator cover M6 12 Nm (8.9 lbf ft) – Screw, bearing retainer M6 12 Nm (8.9 lbf ft) Loctite ® 243™ Screw, camshaft bearing bridge M6 11 Nm (8.1[...]

21 TECHNICA L DATA 160 Screw, valve cover M6 12 Nm (8.9 lbf ft) – Screw, water pump cover M6 12 Nm (8.9 lbf ft) – Nut, exhaust flange M8 22 Nm (16.2 lbf ft) – Screw plug M8 12 Nm (8.9 lbf ft) – Screw, balancer shaft gear M8 20 Nm (14.8 lbf ft) Loctite ® 243™ Screw, return spring, quick shifter M8 12 Nm (8.9 lbf ft) Loctite ® 243™ Stud[...]

21 TECHNICA L DATA 161 Nut, balancer shaft gear M28x1.5 60 Nm (44.3 lbf ft) Loctite ® 243™ 21.3 Capacities 21.3.1 Engine oil Engine oil 1.6 l (1.7 qt.) Engine oil (SAE 15W/50) ( p. 170) 21.3.2 Coolant Coolant 1.1 l (1.2 qt.) Coolant ( p. 169) Coolant (mixed ready to use) ( p. 169) 21.3.3 Fuel Total fuel tank capacity, approx. 11 l (2.9 US gal) S[...]

21 TECHNICA L DATA 162 Front 150 mm (5.91 in) Rear 150 mm (5.91 in) Brake discs - diameter Front 300 mm (11.81 in) Rear 230 mm (9.06 in) Brake discs - wear limit Front 3.6 mm (0.142 in) Rear 3.6 mm (0.142 in) Tire air pressure, solo Front 2.0 bar (29 psi) Rear 2.0 bar (29 psi) Tire air pressure with passenger/full payload Front 2.0 bar (29 psi) Rea[...]

21 TECHNICA L DATA 163 21.5 Electrical system Battery FTZ-9 Battery voltage: 12 V Nominal capacity: 8 Ah Maintenance-free Fuse 75011088010 10 A Fuse 75011088015 15 A Fuse 90111088025 25 A Fuse 75011088030 30 A Headlight H4/socket P43t 12 V 60/55 W Parking light W5W/socket W2.1x9.5d 12 V 5 W Instrument lights and indicator lamps LED Turn signal LED [...]

21 TECHNICA L DATA 164 21.7 Fork Fork part number 90201000044 Fork WP Sus pension Fork length 736 mm (28.98 in) Fork oil 440 ml (14.88 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 170) 21.8 Shock absorber Shock absorber part number 90104010100 Shock absorber WP Sus pension Spring preload Standard 3 clicks Full payload 10 clicks Static sag 15 mm (0.5[...]

21 TECHNICA L DATA 165 Screw, ABS hose clamp M5 8 Nm (5.9 lbf ft) – Screw, brake fluid reservoir of rear brake M5 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, brake line holder, rear M5 8 Nm (5.9 lbf ft) Loctite ® 243™ Screw, fuel pump M5 5 Nm (3.7 lbf ft) – Screw, fuel tank closure flange M5 3 Nm (2.2 lbf ft) – Screw, fuel tank cover M5 4 N[...]

21 TECHNICA L DATA 166 Screw, front seat fixing M6 5 Nm (3.7 lbf ft) – Screw, fuel tank M6 11 Nm (8.1 lbf ft) – Screw, headlight holder M6 11 Nm (8.1 lbf ft) – Screw, headlight mask M6 11 Nm (8.1 lbf ft) – Screw, ignition coil M6 9 Nm (6.6 lbf ft) – Screw, license plate holder M6 14 Nm (10.3 lbf ft) – Screw, magnetic holder on side stan[...]

21 TECHNICA L DATA 167 Screw, handlebar clamp M8 21 Nm (15.5 lbf ft) – Screw, handrail M8 31 Nm (22.9 lbf ft) – Screw, horn M8 7 Nm (5.2 lbf ft) – Screw, rear brake disc M8 30 Nm (22.1 lbf ft) Loctite ® 243™ Screw, rear footrest bracket M8 26 Nm (19.2 lbf ft) Loctite ® 243™ Screw, shift lever M8 15 Nm (11.1 lbf ft) Loctite ® 243™ Scr[...]

21 TECHNICA L DATA 168 Swingarm bearing adjusting ring M22x1 Tighten and ensure that there is no play – Nut, steering head M30x1 Step 1 50 Nm (36.9 lbf ft) 2nd stage (loosen, counter- clockwise) 2 turns Step 3 5 Nm (3.7 lbf ft) –[...]

22 SUBSTAN CES 169 Brake fluid DOT 4 / DOT 5.1 Standard/classific ation – DOT Guideline – Use only brake fluid that complies with the specified standard (see specification s on the container) and that possesses the correspond- ing properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ® – Brake Fluid DOT 5. 1 C[...]

22 SUBSTAN CES 170 Engine oil (SAE 15W/50) Standard/classific ation – JASO T903 MA ( p. 174) – SAE ( p. 174) (SAE 15W/50) Guideline – Use only engine oils that comply with the specified standards (see specification s on the container) and that possess the corresponding properties. Partially synthetic engine oil Recommended supplier Motorex ®[...]

22 SUBSTAN CES 171 Info Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).[...]

23 AUXILIAR Y SUBSTANCES 172 Chain cleaner Recommended supplier Motorex ® – Chain Clean Chain lube for road use Guideline Recommended supplier Motorex ® – Chainlube Road Fuel additive Recommended supplier Motorex ® – Fuel St abilizer Long-life grease Recommended supplier Motorex ® – Bike Gr ease 2000 Motorcycle cleaner Recommended suppl[...]

23 AUXILIAR Y SUBSTANCES 173 Perfect Finish and high gloss polish for paints Recommended supplier Motorex ® – Moto Polish & Shi ne Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ® ?[...]

24 STANDAR DS 174 JASO T903 MA Different technical developme nt directions required a new specification for 4-stroke motorcyc les – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles becau se there was no separate motorcycle specification. Whereas long service intervals are demanded f[...]

INDEX 175 INDEX A ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Antifreeze checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Antilock brake system . . . . . . . . . . . . . . . . . . . . . [...]

INDEX 176 display TRIP F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 distance menu 1 TRIP 1 . . . . . . . . . . . . . . . . . . . . . . . . . 44 distance menu 2 TRIP 2 . . . . . . . . . . . . . . . . . . . . . . . . . 45 filling level display in fuel tank . . . . . . . . . . . . . . . . . . . . 35 function buttons . . . . . .[...]

INDEX 177 G Grab ha ndles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 H Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Headlight adjustment adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 checking . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

INDEX 178 R Rear hu b rubb er dam pers checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Rear sp rocket checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Rear wh eel installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Removing . . . . . . . . . . . . . . .[...]

INDEX 179 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154-156 Turn si gnal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2[...]

*32131 23en* 3213123en 11/2013 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com Photo: Mitterbauer/KTM[...]