KTM RC 390 (2015) manual

OWNER'S MANUAL 20 15 RC 390 EU RC 390 AU RC 390 JP RC 390 ASIA RC 390 BR RC 390 CN RC 390 MY Art. no. 3213249en[...]

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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 Motorrad 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 7.7 Filling level display in fuel tank ........................... 42 7.8 TRIP F display ............................... .................... 43 7.9 Coolant temperature indicator ............................. 44 7.10 Info display .................. ............................ ......... 45 7.11 Riding time/a verage speed menu ..[...]

TABLE OF CONTENTS 5 12.14 Removing the battery cover ................................. 91 12.15 Mounting the battery cover............... ................... 93 12.16 Removing the front spoiler .................................. 93 12.17 Fitting front spoiler .............................. .............. 95 12.18 Removing the left side cover ......[...]

TABLE OF CONTENTS 6 18.2 Changin g the engine oil and oil filter, cleaning the oil screens ................................. ............ 151 18.3 Adding engin e oil ................................. ............ 154 19 CLEANING, CARE ................................. ...................... 156 19.1 Cleanin g the motorcycle .... ...................[...]

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 Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measur es are not taken. Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Indicates a danger that[...]

2 SAFETY ADVICE 10 1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which condu ct exhaust gases. 2 Removal or puncturing of parts of the intake system. 3 Lack of proper maintenance. 4 Replacing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by t[...]

2 SAFETY ADVICE 11 2.6 Protective clothing Warning Risk o f injury   Missing or poor protective clothing presents an increas ed safety risk. – Wea r protective clothing (helmet, boots, gloves, pants and jacket with protecto rs) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal require[...]

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 NOTES 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 resulting from [...]

3 IMPORTA NT NOTES 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 compon ents. For this reason, it may be necessary to inspect or replace parts before the next scheduled service. It is imperati[...]

15[...]

4 VIEW OF VEHICLE 16 4.1 View of vehicle, front left (example) L02250-10[...]

4 VIEW OF VEHICLE 17 1 Horn button ( p. 23) 1 Light switch ( p. 24) 1 High beam flasher button ( p. 24) 1 Turn signal switch ( p. 25) 2 Clutch lever ( p. 22) 3 Filler cap 4 Seat lock ( p. 29) 5 Side stand ( p. 33) 6 Shift lever ( p. 31)[...]

4 VIEW OF VEHICLE 18 4.2 View of vehicle, rear right (example) L02251-10[...]

4 VIEW OF VEHICLE 19 1 Grab handles ( p. 30) 2 Tool set ( p. 30) 3 Ignition/steering lock ( p. 26) 4 Emergency OFF switch ( p. 25) 4 Electric starter button ( p. 26) 5 Throttle grip ( p. 23) 6 Hand brake lever ( p. 22) 7 Passenger footrests ( p. 31) 8 Foot brake lever ( p. 32)[...]

5 SERIAL NUMBE RS 20 5.1 Chassis number 402175-10 The chassis number  is stamped on the right side of the frame under the seat. 5.2 Type lab el 0 0 1 1 402174-10 The type label  is on the right of the frame behind the steering head.[...]

5 SERIAL NUMBE RS 21 5.3 Engine n umber 401949-10 The engine number  is stamped on the left side of the engine under the engine sprocket. 5.4 Key num ber 402245-10 The key number  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 L02111-10 The clutch lever  is fitted on the left side of the handlebar. 6.2 Hand bra ke leve r L02112-10 The hand brake lever  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 L02112-11 The throttle grip  is fitted on the right side of the handlebar. 6.4 Horn button L02113-10 The horn button  is fitted on the left side of the handlebar. Possible states • Horn butto n in neutral position • Horn butto n pressed – The horn is operated in this position.[...]

6 CONTROL S 24 6.5 Light switch L02113-11 The light switch  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 – The light switch is turned upwards. In this position, the low beam, the high beam and the tail li[...]

6 CONTROL S 25 6.7 Turn signal switch L02113-13 The turn signal switch  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 presse[...]

6 CONTROL S 26 6.9 Electric starter button L02114-11 The electric starter button  is fitted on the right side of the handlebar. Possible states • Elec tric starter button in basic position • Elec tric starter button pressed – In this position, the electric starter is actuated. 6.10 Ignition/steerin g lock L02115-01 The ignition/steering lo[...]

6 CONTROL S 27 6.11 Locking the steering Note Danger of damage   The parked vehicle may roll away or fall over. – Alwa ys place the vehicle on a firm and even surface. 400732-01 – Park the vehicle . – Turn the handleb ar all the way to the left. – Inse rt the key into the ignition/handlebar lock, press in, and turn to the left. Remove the[...]

6 CONTROL S 28 6.13 Opening the filler cap Danger Fire ha zard   Fuel is highly flammable. – Nev er refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediate ly. – The fuel in the fuel tank expands whe[...]

6 CONTROL S 29 – Rem ove the ignition key. 6.14 Closing the filler cap L02117-01 Warning Fire ha zard   Fuel is highly flammable, poisono us and harmful to your health. – Afte r 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 w[...]

6 CONTROL S 30 6.16 Tool set L02274-10 The tool set  is in the storage compartment under the seat. 6.17 Grab handles L02256-10 The grab handles  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 31 6.18 Passenger footrests L02273-01 The passenger footrests can be folded in and out. Possible states • Pass enger footrests folded up – For operation without a passenger. • Pass enger footrests folded down – For operation with a passenger. 6.19 Shift lever 401950-10 Shift lever  is mounted on the left side of the engine.[...]

6 CONTROL S 32 401950-11 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 6.20 Foot brake lever 402177-10 Foot brake lever  is located in front of the right footrest. The foot brake lever is used to activate the rear brake.[...]

6 CONTROL S 33 6.21 Side stand 402029-10 The side stand  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 folde d out – The vehicle can be[...]

7 COMBINA TION INSTRUME NT 34 7.1 Overview 401685-10 1 Display ( p. 41) 2 Function buttons ( p. 39) 3 Info display ( p. 45) 4 Indicator lamps ( p. 40)[...]

7 COMBINA TION INSTRUME NT 35 7.2 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 li[...]

7 COMBINA TION INSTRUME NT 36 7.3 Warning notes 401309-01 Low O il Press ure appears on the info display if the oil pressure is too low. 401310-01 Low F uel Lev el appears on the info display if the fuel level reaches the reserve mark.[...]

7 COMBINA TION INSTRUME NT 37 401311-01 High C oolant 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 B attery appears on the info display if the battery vo[...]

7 COMBINA TION INSTRUME NT 38 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.[...]

7 COMBINA TION INSTRUME NT 39 7.4 Function buttons 401685-12 You can change the display mode with the MODE button  . Possible display modes are total distance traveled ( TRIP 1 ), distance 1 ( ODO ) and distance 2 ( TRIP 2 ). Pressing and holding the SET button  resets the distance 1 ( TRIP 1 ) and distance 2 ( TRIP 2 ) functions to 0.0 and b[...]

7 COMBINA TION INSTRUME NT 40 7.5 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 wa[...]

7 COMBINA TION INSTRUME NT 41 7.6 Display 401685-11 The speed  is shown in kilometers per hour km/h or in miles per hour mph . The tachometer  shows the engine speed in revolutions per minute. The gear display  shows the engaged gear. The coolant temperature appears in segment  . The time appears in segment  . The filling level in th[...]

7 COMBINA TION INSTRUME NT 42 7.7 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.[...]

7 COMBINA TION INSTRUME NT 43 7.8 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 a[...]

7 COMBINA TION INSTRUME NT 44 7.9 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 C oolant Temperature . Possible states • Engi ne cold – Up to three bars light up. • En[...]

7 COMBINA TION INSTRUME NT 45 7.10 Info display 401291-10 Various warning notes appear on info display  . If the general warning lamp lights up, the corresponding warning note is shown on the info display.[...]

7 COMBINA TION INSTRUME NT 46 7.11 Riding time/average speed menu 401334-01 Condition Alternative 1 • The ignitio n is on. • The motor cycle is stationary. Alternative 2 • The ignitio n is on. • The motor cycle is moving. – Pres s the SET button briefly and repeatedly until the desired info display appears. The riding time and average spe[...]

7 COMBINA TION INSTRUME NT 47 In this menu, the average speed and the average fuel consumption 1 are displayed in L/100 km (or L/100 miles). 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[...]

7 COMBINA TION INSTRUME NT 48 Press the SET button briefly. Next display mode on the info display 7.14 Average fuel consumption 2/service menu 401467-01 Condition Alternative 1 • The ignitio n is on. • The motor cycle is stationary. Alternative 2 • The ignitio n is on. • The motor cycle is moving. – Pres s the SET button briefly and repea[...]

7 COMBINA TION INSTRUME NT 49 7.15 Service/range menu 401468-01 Condition Alternative 1 • The ignitio n is on. • The motor cycle is stationary. Alternative 2 • The ignitio n is on. • The motor cycle is moving. – Pres s the SET button briefly and repeatedly until the desired info display appears. This menu shows the distance to the next se[...]

7 COMBINA TION INSTRUME NT 50 7.16 Range/riding time menu 401469-01 Condition Alternative 1 • The ignitio n is on. • The motor cycle is stationary. Alternative 2 • The ignitio n is on. • The motor cycle is moving. – Pres s the SET button briefly and repeatedly until the desired info display appears. The range and the riding time are displ[...]

7 COMBINA TION INSTRUME NT 51 7.17 Total distance menu ODO 401303-01 Condition Alternative 1 • The ignitio n is on. • The motor cycle is stationary. Alternative 2 • The ignitio n is on. • The motor cycle is moving. – Pres s the MODE button briefly and repeatedly until ODO appears on the display. ODO shows the total distance covered. Info [...]

7 COMBINA TION INSTRUME NT 52 TRIP 1 show s the distance covered since the last reset. For example, the distance from one refueling stop to the next. TRIP 1 is always running and counts up to 999.9 . 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 7.19 Distance menu 2 TRI[...]

7 COMBINA TION INSTRUME NT 53 7.20 Setting kilometers or miles Info Make the country-specific setting. Condition The ignition is on. The motorcycle is stationary. 401303-01 – Pres s the MODE button briefly and repeatedly until ODO appears on the display. – Pres s the MODE button for 5 - 10 seconds. The display changes from km/h to mph or from m[...]

7 COMBINA TION INSTRUME NT 54 401303-01 – Pres s the MODE button briefly and repeatedly until ODO appears on the display. – Pres s the MODE and SET buttons for 5 - 10 seconds. The time display begins to flash. – Set the hours display using the MODE button . – Set the minutes displa y using the SET button. – Pres s the MODE and SET buttons[...]

7 COMBINA TION INSTRUME NT 55 The display RPM 1 goes out and the set speed is stored. 7.23 Adjusting the shift speed RPM 2 Condition The ignition is on. The motorcycle is stationary. 401308-01 – Pres s the MODE button briefly and repeatedly until TRIP 2 appears on the display. – Pres s the SET button for 5 - 10 seconds. The display RPM 2 appear[...]

8 PREPARIN G FOR USE 56 8.1 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 influenc e of alcohol, drugs and certain medications or physically or mentally impaired. Warning Risk o f injury   Missing or poor protective clothing present[...]

8 PREPARIN G FOR USE 57 – Mak e 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. – Befo re your first trip, read the entire operating instructions carefully. – Get to know the controls. – Get used to handling the moto[...]

8 PREPARIN G FOR USE 58 8.3 Loading the vehicle Warning Danger of accidents   Unstabl e handling characteristics. – Do not exceed the maximu m permitted weight and axle loads. The overall weight consists of: motorcycle operatio nal and with a full tank, driver and passenger with protective clothing and helmet, baggag e. Warning Danger of accide[...]

8 PREPARIN G FOR USE 59 – 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 maxim um permitted weight and the axle loads. Guideline Maximum permissible overal l weight 335 kg (739 lb.) Maxim[...]

9 RIDING INSTRUC TIONS 60 9.1 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. – Che ck the engine oil level. ( p. 151) – Che ck the brake fluid level of the front brake. ( p. 104) – Che ck th[...]

9 RIDING INSTRUC TIONS 61 9.2 Starting Danger Danger of poisoning   Exhaust gase s are toxic and inhaling them may result in unconsciousness and/or death. – Whe n 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 [...]

9 RIDING INSTRUC TIONS 62 B00782-10 – Sit on the vehicle, take the weight off of the side stand, and move up all the way. – Turn the emerge ncy OFF switch to the position . – Switc h 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 fun[...]

9 RIDING INSTRUC TIONS 63 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  button for 3 – 5 seconds. The ABS warning lamp starts flashing; ABS is deactivated. 9.3 Starting off – Pull the clutch [...]

9 RIDING INSTRUC TIONS 64 Warning Danger of accidents   Malfunc tions caused by incorrect ignition key position. – Do not change the ignition key positio n during a journey. Warning Danger of accidents   Distracti on from traffic activity by adjustments to the vehicle. – Mak e all adjustments when the vehicle is at a standstill. Warning Ris[...]

9 RIDING INSTRUC TIONS 65 Warning Danger of accidents   Unstabl e handling characteristics due to slipped baggage. – Che ck the way your baggage is fixed regularly. Warning Danger of accidents   Lack of roadworthin ess. – Afte r a fall, check the vehicle as usual before preparing for use. Note Engine failure   Overheating of engine. – I[...]

9 RIDING INSTRUC TIONS 66 – Acce lerate 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[...]

9 RIDING INSTRUC TIONS 67 Warning Danger of accidents   Delayed brake actio n on salted roads. – The re 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 t[...]

9 RIDING INSTRUC TIONS 68 9.6 Stopping, parking Warning Risk o f misap propriation   Usa ge by unauthorized persons. – Nev er 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 com[...]

9 RIDING INSTRUC TIONS 69 – Swit ch 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 en[...]

9 RIDING INSTRUC TIONS 70 401448-01 – Switc h off the engine and remove the ignition key. – Use tensi on belts or other suitable devices to secure the motorcycle against accidents or falling over. 9.8 Refueling Danger Fire ha zard   Fuel is highly flammable. – Nev er refuel the vehicle near open flames or burning cigarettes, and always swit[...]

9 RIDING INSTRUC TIONS 71 – Only refue l 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. L02129-10 – Switc h off the engine. – Open the filler cap. ( p. 28) – Fi[...]

10 SERVICE SCHED ULE 72 10.1 Additional information Any further work that results from the required work or from the recommended work must be ordered separately and can be invoiced sepa- rately. 10.2 Required work Every two years Every year Every 15,000 km (9,300 mi) Every 7,500 km (4 ,650 m i) After 1 ,000 km (620 mi) Read out the fault memory usi[...]

10 SERVICE SCHED ULE 73 Every two years Every year Every 15,000 km (9,300 mi) Every 7,500 km (4 ,650 m i) After 1 ,000 km (620 mi) Check the chain tension. ( p. 85) ○ ● ● ● ● Check the coolant level in the compensating tank. ( p. 139) ○ ● ● ● ● Check that the radiator fan is functioning properly. ○ ● ● ● ● Change the a[...]

10 SERVICE SCHED ULE 74 10.3 Recommended work Every four years Every year Every 7,500 km (4 ,650 m i) After 1 ,000 km (620 mi) Check the swingarm bearing. ● Check the wheel bearings. ● Grease all moving parts (e.g. side stand, hand lever, chain, ...) and check for smooth operation. ○ ● ● ● Empty the drainage hoses. (RC 390 BR, RC 390 CN[...]

11 TUNING THE CHASSIS 75 11.1 Adjusting the spring preload of the shock absorber Warning Danger of accidents   Modifica tions to the suspension settings can seriously alter the vehicle's ride behavior. – Foll owing modifications, ride slowly at first to get the feel of the new ride behavior. Info The spring preload defines the initial situ[...]

11 TUNING THE CHASSIS 76 11.2 Adjusting the shift lever Info The adjustment range of the shift lever is limited. L02272-10 – Loosen nut  , holding the threaded rod  . Info Nut  has a left-handed thread. – Loosen nut  , holding the threaded rod  . – Adjust the shift lever by turning shift rod  . Guideline Shift rod adjustment[...]

11 TUNING THE CHASSIS 77 – Tighten nut  , holding the threaded rod  . Guideline Nut, shift rod M6LH 10 Nm (7.4 lbf ft) – Chec k the shift lever to ensure it is functioning properly and can move freely.[...]

12 SERVICE WORK ON THE CHASSIS 78 12.1 Raising the motorcycle with the rear wheel stand Note Danger of damage   The parked vehicle may roll away or fall over. – Alwa ys place the vehicle on a firm and even surface. L02255-01 – Mou nt the supports of the wheel stand. – Inse rt the adapter in the rear wheel stand. Bushing kit for lifting gear[...]

12 SERVICE WORK ON THE CHASSIS 79 402029-10 – Secu re the motorcycle against falling over. – Remove the rear wheel stand and lean the vehicle on the side stand  . 12.3 Raising the motorcycle with the front wheel stand Note Danger of damage   The parked vehicle may roll away or fall over. – Alwa ys place the vehicle on a firm and even sur[...]

12 SERVICE WORK ON THE CHASSIS 80 L02253-01 – Mov e the handlebar to the straight-ahead position. Position the wheel stand. Adapter (61029955620) Front wheel stand (61029055500) Info Always raise the rear of the motorcycle first. – Rais e the front of the motorcycle. 12.4 Taking the motorcycle off of the front wheel stand Note Danger of damage [...]

12 SERVICE WORK ON THE CHASSIS 81 M00453-10 – Mount protection cap  . Finishing work – Take the motorc ycle off of the rear wheel stand. ( p. 78) 12.5 Removing the front rider's seat M00454-10 – Insert the ignition key in seat lock  and turn it clockwise. – Rais e the rear of the front rider's seat, pull it toward the rear, [...]

12 SERVICE WORK ON THE CHASSIS 82 12.6 Mounting the front rider's seat 401921-10 – Attach recesses  on the front rider's seat to the fuel tank, push the front rider's seat forward, and lower at the rear. Catch  engages in the recess. – Chec k that the front rider's seat is correctly mounted. 12.7 Removing the passenger[...]

12 SERVICE WORK ON THE CHASSIS 83 12.8 Mounting the passenger seat M00449-10 Main work – Attach hook  into bracket  . – Lowe r the passenger seat and push back. L02191-11 – Mount and tighten screw  with the washer. Guideline Screw, passenger seat M6 7 Nm (5.2 lbf ft) Warning Danger of accidents   The passenge r seat can come loose [...]

12 SERVICE WORK ON THE CHASSIS 84 12.9 Checking for chain dirt accumulation 400678-01 – Chec k the chain for coarse dirt accumulation. » If the chain is very dirty: – Clea n the chain. ( p. 84) 12.10 Cleaning the chain Warning Danger of accidents   Oil or grease on the tires reduces their grip. – Rem ove oil and grease with a suitable clea[...]

12 SERVICE WORK ON THE CHASSIS 85 Info The service life of the chain depends largely on its maintenance. Preparatory work – Rais e the motorcycle with the rear wheel stand. ( p. 78) 400725-01 Main work – Clea n the chain regularly. – Rins e off loose dirt with a soft jet of water. – Rem ove old grease remains with chain cleaner. Chain clean[...]

12 SERVICE WORK ON THE CHASSIS 86 L02261-10 – Lean the motorc ycle 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  . Info The upper chain section  must be taut. Chain wear is not always even, so you should repeat this measurement at[...]

12 SERVICE WORK ON THE CHASSIS 87 12.12 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 transmiss ion (chain, engine sprocket, rear sprocket, bearings in the transmission and in the rear wheel) will be under additional load. In[...]

12 SERVICE WORK ON THE CHASSIS 88 L02150-10 Main work – Loosen nut  . – Loosen nuts  . – Adjust the chain tension by turning adjusting screws  on the left and right. Guideline Chain tension 5… 7 mm (0.2… 0.28 in) Turn adjusting screws  on the left and right so that the markings on the left and right chain adjusters  are in [...]

12 SERVICE WORK ON THE CHASSIS 89 12.13 Checking the chain, rear sprocket, and engine sprocket 100132-10 – Chec k the rear sprocket and engine sprocket for wear. » If the rear sprocket and engine sprocke t are worn: – Cha nge the power set. Info The engine sprocket, rear sprocket, and chain should always be replaced together.[...]

12 SERVICE WORK ON THE CHASSIS 90 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  . Guideline Weight, chain wear measurement 15 kg (33 lb.) – Measure the distance  of 20 chain links in the lower chain section. Info Chain wear is not always even, so you should re[...]

12 SERVICE WORK ON THE CHASSIS 91 L02167-10 – Push the chain up in the area behind the chain guide. – Chec k the chain sliding guard for wear. » If the chain sliding guard has lost material due to wear to the extent that, in area  , the drilled hole of screw  is visible from above: – Cha nge the chain sliding guard. – Chec k that the[...]

12 SERVICE WORK ON THE CHASSIS 92 M00450-10 Main work – Pull loop  toward the rear. – Pull battery cover  forward and remove toward the top.[...]

12 SERVICE WORK ON THE CHASSIS 93 12.15 Mounting the battery cover M00451-10 Main work – Position battery cover  and pull toward the rear. The battery cover engages with an audible click. – Chec k the battery cover is seated correctly. Finishing work – Mou nt the front rider's seat. ( p. 82) 12.16 Removing the front spoiler Preparator[...]

12 SERVICE WORK ON THE CHASSIS 94 L02257-11 – Remove screw  . L02263-12 – Remove screws  . G01721-13 – Remove screw  . – Remove screw  . – Take off the front spoiler.[...]

12 SERVICE WORK ON THE CHASSIS 95 12.17 Fitting front spoiler G01721-14 Main work – Posi tion the front spoiler. – Mount and tighten screw  . Guideline Screw, front spoiler retaining bracket, rear, on engine M6 9 Nm (6.6 lbf ft) – Mount and tighten screw  . Guideline Screw, front spoiler retaining bracket, rear, on engine M6 9 Nm (6.6 l[...]

12 SERVICE WORK ON THE CHASSIS 96 L02257-12 – Mount and tighten screw  . Guideline Screw, front spoiler, right, on footrest bracket M6 7 Nm (5.2 lbf ft) L02258-12 – Mount and tighten screws  . Guideline Screw, front spoiler M6 7 Nm (5.2 lbf ft) Finishing work – Insta ll the left side cover. ( p. 98) – Insta ll the right side cover. ( [...]

12 SERVICE WORK ON THE CHASSIS 97 12.18 Removing the left side cover L02268-10 – Remove screws  . – Remove screws  . – Pull off holding lug in area  . M00456-10 – Remove expanding rivet  .[...]

12 SERVICE WORK ON THE CHASSIS 98 L02260-10 – Swin g the side cover outward. – Pull hose  out of hose guide  . – Take off the side cover. 12.19 Installing the left side cover L02260-11 – Position hose  in hose guide  .[...]

12 SERVICE WORK ON THE CHASSIS 99 L02268-11 – Posi tion the side cover. – Mount and tighten screws  . Guideline Screw, side cover M6 7 Nm (5.2 lbf ft) – Push on the side cover in area  . The holding lug engages in the drilled hole on the front spoiler. – Mount and tighten screws  . Guideline Screw, side cover on front mask M6 6 Nm [...]

12 SERVICE WORK ON THE CHASSIS 100 12.20 Removing the right side cover L02267-10 – Remove screws  . – Remove screws  . – Pull off holding lug in area  . M00455-10 – Remove expanding rivet  . – Take off the side cover.[...]

12 SERVICE WORK ON THE CHASSIS 101 12.21 Installing the right side cover L02267-10 – Posi tion the side cover. – Mount and tighten screws  . Guideline Screw, side cover M6 7 Nm (5.2 lbf ft) – Push on the side cover in area  . The holding lug engages in the drilled hole on the front spoiler. – Mount and tighten screws  . Guideline S[...]

13 BRAKE SYSTEM 102 13.1 ABS/antilock brake system 402052-10 The ABS unit  , which consists of a hydraulic unit, ABS control unit, and return pump, is installed under the seat. A wheel speed sensor  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 w[...]

13 BRAKE SYSTEM 103 The ABS warning lamp  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 bra[...]

13 BRAKE SYSTEM 104 – Cha nge the brake discs. – Chec k the front and rear brake discs for damage, cracking, and deformation. » If the brake disc shows signs of damage, cracking , or deformation: – Cha nge the brake discs. 13.3 Checking the brake fluid level of the front brake Warning Danger of accidents   Failure of the brake system. – [...]

13 BRAKE SYSTEM 105 13.4 Adding front brake fluid 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 [...]

13 BRAKE SYSTEM 106 L02133-10 Main work – Mov e the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws  . – Remove cover  with membrane  . – Add brake fluid to level  . Guideline Level  5 mm (0.2 in) Brake fluid DOT 4 / DOT 5.1 ( p. 184) – Posi tion the cover with the membrane. Mount an[...]

13 BRAKE SYSTEM 107 M00457-10 – Check the brake linings for minimum thickness  . Minimum thickness  ≥ 1 mm ( ≥ 0.04 in) » If the minimum thickn ess is less than specified: – Cha nge the front brake linings. – Chec k the brake linings for damage and cracking. » If there is wear or tearing: – Cha nge the front brake linings. 13.6 [...]

13 BRAKE SYSTEM 108 M00458-10 – Stan d the vehicle upright. – Chec k the brake fluid level in the brake fluid reservoir. » If the fluid level reaches the MIN marking  : – Add rear brake fluid. ( p. 108) 13.7 Adding rear brake fluid Warning Danger of accidents   Failure of the brake system. – If the brake fluid level falls below the MI[...]

13 BRAKE SYSTEM 109 Warning Environmental hazard   Hazardous substances caus e environmental damage. – Oil, greas e, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sea[...]

13 BRAKE SYSTEM 110 Note Danger of accidents   Reduced brak ing efficiency caused by damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are destroyed. Check the brake linings regularly. M00460-10 – Check the bra[...]

13 BRAKE SYSTEM 111 M00461-10 – Disconnect spring  . – Mov e the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel  . Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) » If the free travel does not meet specification s: – Adju st the free trav[...]

13 BRAKE SYSTEM 112 M00461-11 – Disconnect spring  . – Release nut  and use screw  to adjust the specified free travel  . Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) Info The range of adjustment is limited. – Hold screw  and tighten nut  . – Attach spring  .[...]

14 WHEELS, TIRES 113 14.1 Removing the front wheel Preparatory work – Rais e the motorcycle with the rear wheel stand. ( p. 78) – Rais e the motorcycle with the front wheel stand. ( p. 79) L02277-10 Main work – Remove screws  and push the fender to the side. – Remove screw  and pull wheel speed sensor  out of the hole. – Loosen s[...]

14 WHEELS, TIRES 114 14.2 Installing the front wheel Warning Danger of accidents   Reduced brak ing efficiency due to oil or grease on the brake discs. – Alwa ys keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. L02183-11 Main work – Remove spacers  . – Chec k the wheel bearing for damage and [...]

14 WHEELS, TIRES 115 M00463-10 – Clean the thread of the wheel spindle and screw  . – Posi tion the front wheel and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw  . Guideline Screw, front wheel spindle M8 20 Nm (14.8 lbf ft) – Position wheel speed sensor  in the drill hole. Mount an[...]

14 WHEELS, TIRES 116 14.3 Removing the rear wheel Preparatory work – Rais e the motorcycle with the rear wheel stand. ( p. 78) L02150-11 Main work – Remove screw  and pull wheel speed sensor  out of the hole. – Remove nut  and the washer. Remove chain adjuster  . – Holding the rear wheel, withdraw wheel spindle  with the w[...]

14 WHEELS, TIRES 117 14.4 Installing the rear wheel Warning Danger of accidents   Reduced brak ing efficiency due to oil or grease on the brake discs. – Alwa ys keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Danger of accidents   No braking effect when operati ng the rear brake. – Afte[...]

14 WHEELS, TIRES 118 L02150-13 – Pull the rear wheel back and mount wheel spindle  with the washer and chain adjuster  . Info Mount the left and right chain adjusters  in the same position. – Mount nut  and washer. – Push the rear wheel forward so that the chain adjusters are in contact with the screws, and tighten nut  . Guide[...]

14 WHEELS, TIRES 119 Preparatory work – Rais e the motorcycle with the rear wheel stand. ( p. 78) – Rem ove the rear wheel. ( p. 116) L02153-10 Main work – Check bearing  . » If the bearing is damaged or worn: – Cha nge the rear wheel bearing. – Check the rubber dampers  of the rear hub for damage and wear. » If the rubber dampers[...]

[...]

14 WHEELS, TIRES 121 » If the tread depth is less than the minimum permissible depth : – Cha nge the tires. – Chec k 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 [...]

14 WHEELS, TIRES 122 » If the tire air pressure does not meet specification s: – Corr ect the tire air pressure. – Mou nt the dust cap.[...]

15 ELECTRIC AL SYSTEM 123 15.1 Removing the battery Warning Risk o f injury   Battery acid and battery gases cause serious chemical burns . – Kee p batteries out of the reach of children. – Wea r suitable protective clothing and goggles. – Avo id contact with battery acid and battery gases. – Kee p sparks and open flames away from the bat[...]

15 ELECTRIC AL SYSTEM 124 L02157-11 – Pull back the positive terminal cover  . – Disconnect the positive cable  of the battery. – Detach rubber band  . – 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 safet[...]

15 ELECTRIC AL SYSTEM 125 L02156-11 – Connect the negative cable  of the battery. – Position the negative terminal cover  . Finishing work – Mou nt the battery cover. ( p. 93) – Mou nt the front rider's seat. ( p. 82) – Set the clock. ( p. 53) 15.3 Recharging the battery Warning Risk o f injury   Battery acid and battery gase[...]

15 ELECTRIC AL SYSTEM 126 Warning Environmental hazard   The battery contains elements that are harmful to the environment. – Do not dispose of batteries with the househo ld waste. Dispose of a defective battery in an environmentally friendly manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used [...]

15 ELECTRIC AL SYSTEM 127 L02139-10 Main work – Conn ect 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 rem[...]

15 ELECTRIC AL SYSTEM 128 15.4 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 prescrib ed amperage. Never bypass or repair fuses. Info Two fuses for the ABS are located under the protective cap next to the negative terminal of the battery. These fuses[...]

15 ELECTRIC AL SYSTEM 129 Fuse (75011088015) ( p. 177) Tip Replace spare fuse  in the fuse box so that it is available if needed. – Mou nt the protection cap. L02158-11 To cha nge th e fuse of the ABS return pump: – Take off the protection cap and remove fuse  . Warning Fire ha zard   The electrical system can be overloaded if the wrong[...]

15 ELECTRIC AL SYSTEM 130 15.5 Changing the fuses of individual power consumers Info The fuse box with the main fuse and fuses of the individual power consumers is located next to the positive terminal of the battery. Preparatory work – Switc h off all power consumers and switch off the engine. – Rem ove the front rider's seat. ( p. 81) ?[...]

15 ELECTRIC AL SYSTEM 131 Info A defective fuse is indicated by a burned-out fuse wire  . Warning Fire ha zard   The electrical system can be overloade d if the wrong fuses are used. – Use only fuses with the prescrib ed amperage. Never bypass or repair fuses. – Use spare fuses with the correct rating only. Fuse (75011088005) ( p. 177) Fus[...]

15 ELECTRIC AL SYSTEM 132 15.6 Changing the low beam bulb Note Damage to reflector   Reduce d brightness. – Grea se on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting. Preparatory work – Switc h off all power consumers and switch off the engine. L02161-10 Mai[...]

15 ELECTRIC AL SYSTEM 133 L02166-10 – Posi tion the socket with the low beam bulb in the headlight housing. – Turn the socket clock wise. – Chec k that the lighting is functioning properly. 15.7 Changing the high beam bulb Note Damage to reflector   Reduce d brightness. – Grea se on the lamp will evaporate due to the heat and be deposited[...]

15 ELECTRIC AL SYSTEM 134 L02162-10 Main work – Turn socket  counterclockwise . – Pull the socket with high beam bulb  out of the headlight housing. – Disconnect the socket with the high beam bulb from connector  and remove. – Conn ect the new socket with the high beam bulb to the connector. High beam (H11 / Sockel PGJ19-2) ( p. 17[...]

15 ELECTRIC AL SYSTEM 135 15.8 Checking the low beam headlight adjustment 0 0 A A 0 0 B B 400726-10 – Posi tion 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  under the first mark. Guideline Distance  5 cm (2 in)[...]

15 ELECTRIC AL SYSTEM 136 15.9 Checking the high beam headlight adjustment 0 0 B B 0 0 A A 0 0 B B 400575-10 – Posi tion 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  under the first mark. Guideline Distance  5 [...]

15 ELECTRIC AL SYSTEM 137 15.10 Adjusting the headlight range of the low beam L02164-10 Main work – Adjust the beam range of the low beam by turning screw  . 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 the low beam headlig[...]

16 COOLING SYSTE M 138 16.1 Cooling system L02259-10 Water pump  in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap  . Heat expansion causes excess coolant to flow into compensating tank  . When the temperature falls, this surplus coolant is sucked bac[...]

16 COOLING SYSTE M 139 402242-10 The coolant is cooled by the air stream and a radiator fan  , which is controlled by a ther- moswitch. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect. 16.2 Checking the coolant level in the compensating tank Warning Danger of scalding   During motorcy cle ope[...]

16 COOLING SYSTE M 140 Warning Danger of poisoning   Coolant is poisonou s and a health hazard. – Coo lant 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 swal[...]

16 COOLING SYSTE M 141 16.3 Checking the antifreeze and coolant level Warning Danger of scalding   During motorcy cle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiato r hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case o[...]

16 COOLING SYSTE M 142 » If the coolant level does not meet specificat ions: – Corr ect the coolant level. Coolant ( p. 184) – Mou nt the cap of the compensating tank. L02266-11 – Remove radiator cap  . – Chec k the coolant antifreeze. − 25… − 45 °C ( − 13… − 49 °F) » If the coolant antifree ze does not meet specification[...]

16 COOLING SYSTE M 143 16.4 Correcting the coolant level in the compensating tank Warning Danger of scalding   During motorcy cle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiato r hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool dow[...]

16 COOLING SYSTE M 144 16.5 Draining the coolant Warning Danger of scalding   During motorcy cle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiato r hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse imm[...]

16 COOLING SYSTE M 145 Guideline Plug, water pump drain hole M6 8 Nm (5.9 lbf ft) 16.6 Filling/bleedin g the cooling system Warning Danger of poisoning   Coolant is poisonou s and a health hazard. – Coo lant 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[...]

16 COOLING SYSTE M 146 L02265-10 – Release bleeder screw  by three turns. – Tilt the vehicle slightl y to the right. – Pour in coolant until it emerges without bubbl es at the bleeder screw, and then mount and tighten the bleeder screw immediately. Coolant ( p. 184) – Fill the radiator compl etely with coolant. Mount the radiator cap. ?[...]

16 COOLING SYSTE M 147 – Insta ll the right side cover. ( p. 101)[...]

17 TUNING THE ENGINE 148 17.1 Checking the play in the throttle cable 400192-11 – Chec k the throttle grip for smooth operation. – Mov e the handlebar to the straight-ahead position. Move the throttle grip back and forth to ascertain play  in the throttle cable. Throttle cable play 3… 5 mm (0.12… 0.2 in) » If the throttle cable play doe[...]

17 TUNING THE ENGINE 149 17.2 Adjusting the play in the throttle cable M00452-10 – Mov e the handlebar to the straight-ahead position. – Push back sleeve  . – Loosen lock nut  . – Adjust the play in the throttle cable by turning adjusting screw  . Guideline Throttle cable play 3… 5 mm (0.12… 0.2 in) – Tighten lock nut  . ?[...]

17 TUNING THE ENGINE 150 » If the clutch lever play changes: – Che ck the routing of the clutch cable. 17.4 Adjusting the clutch cable play L02155-10 – Mov e the handlebar to the straight-ahead position. – Push back sleeve  . – Loosen lock nut  . – Adjust the play in the clutch level  by turning adjusting screw  . Guideline C[...]

18 SERVICE WORK ON THE ENGINE 151 18.1 Checking the engine oil level Condition The engine is at operating temperature. Preparatory work – Stan d the motorcycle upright on a horizontal surface. L02257-10 Main work – Chec k the engine oil level. Info After switching off the engine, wait one minute before checking the level. The engine oil must be[...]

18 SERVICE WORK ON THE ENGINE 152 Info Drain the engine oil only when the engine is warm. Preparatory work – Rem ove the right side cover. ( p. 100) – Rem ove the left side cover. ( p. 97) – Rem ove the front spoiler. ( p. 93) – Stan d the motorcycle on its side stand on a horizontal surface. L02270-10 Main work – Plac e a suitable contai[...]

18 SERVICE WORK ON THE ENGINE 153 101918-10 – Remove screws  . Remove the oil filter cover  with the O-ring. – Pull oil filter  out of the oil filter housing. Circlip pliers reverse (51012011000 ) – Com pletely drain the engine oil. – Thor oughly clean the parts and sealing area. L02271-10 – Insert oil filter  . – Lubricate [...]

18 SERVICE WORK ON THE ENGINE 154 401955-12 – Remove the oil filler plug  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. 184) – Insta ll and tighten the oil filler plug with O-ring. Danger Danger of poisoning   Exhaust gase s are toxic and inhaling them may result [...]

18 SERVICE WORK ON THE ENGINE 155 0 0 1 1 401955-10 Main work – Remove the oil filler plug  with the O-ring from the clutch cover and fill up with engine oil. Engine oil (SAE 15W/50) ( p. 184) Info For optimal performance of the engine oil, do not mix different types of engine oil. If appropriate, change the engine oil. – Insta ll and tighte[...]

19 CLEANING , CARE 156 19.1 Cleaning the motorcycle Note Material damage   Damage and destruction of components by high-pressur e cleaning equipment. – Whe n cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors , cables, bearings, etc. Maintain a minimum distance of 60 cm betwe[...]

19 CLEANING , CARE 157 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 rinsin g the motorcycle [...]

19 CLEANING , CARE 158 Perfect Finish and high gloss polish for paints ( p. 187) Info Do not polish parts that were matte when delivered as this would strongly impair the material quality. – Trea t all plastic parts and powder-coated parts with a mild cleaning and care product. Special cleaner for glossy and matte paint finishes, metal and plasti[...]

19 CLEANING , CARE 159 – Trea t 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. – Clea n the chain. ( p. 84)[...]

20 STORAGE 160 20.1 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[...]

20 STORAGE 161 – Rais e the motorcycle with the front wheel stand. ( p. 79) – Cove r 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 escapin g, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up proper[...]

21 TROUBLE SHOOTING 162 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. 61) Battery discharged – Rech arge the battery. ( p. 125) Fuse 1 , 3 , 4 , or 7 is blown – Chan ge the fuses of individual power consumers. ( p. 130) No g[...]

21 TROUBLE SHOOTING 163 Faults Possible cause Actio n Engine overheats Defect in radiator fan system – Chec k the radiator fan system. 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. Engine dies during the trip Lack of fuel – Refu el. ( p. 70[...]

21 TROUBLE SHOOTING 164 Faults Possible cause Actio n Battery discharged Battery is not being charged by alter- nator – Chec k the charging voltage. – Chec k the open-circuit current. The combination instrument shows nothing on the display Fuse 7 is blown – Chan ge the fuses of individual power consumers. ( p. 130) – Set the clock. ( p. 53)[...]

22 FLASH CODE 165 Blink code of FI warning lamp (MIL) 02 FI warning lamp ( MIL ) flashes 2x short Error le vel co ndition Crankshaft position sensor - measureme nt range or power problem Blink code of FI warning lamp (MIL) 06 FI warning lamp ( MIL ) flashes 6x short Error le vel co ndition Throttle position sensor circuit A - input signal too low T[...]

22 FLASH CODE 166 Blink code of FI warning lamp (MIL) 13 FI warning lamp ( MIL ) flashes 1x long, 3x short Error le vel co ndition Intake air temperature sensor - input signal too low Intake air temperature sensor - input signal too high Blink code of FI warning lamp (MIL) 14 FI warning lamp ( MIL ) flashes 1x long, 4x short Error le vel co ndition[...]

22 FLASH CODE 167 Blink code of FI warning lamp (MIL) 17 FI warning lamp ( MIL ) flashes 1x long, 7x short Error le vel co ndition Lambda sensor - circuit fault Lambda sensor - input signal too low Lambda sensor - input signal too high Lambda sensor - no function Blink code of FI warning lamp (MIL) 18 FI warning lamp ( MIL ) flashes 1x long, 8x sho[...]

22 FLASH CODE 168 Blink code of FI warning lamp (MIL) 22 FI warning lamp ( MIL ) flashes 2x long, 2x short Error le vel co ndition Engine speed signal - circuit fault Engine speed signal - input signal too low Engine speed signal - input signal too high Blink code of FI warning lamp (MIL) 23 FI warning lamp ( MIL ) flashes 2x long, 3x short Error l[...]

22 FLASH CODE 169 Blink code of FI warning lamp (MIL) 26 FI warning lamp ( MIL ) flashes 2x long, 6x short Error le vel co ndition Sensor A reference voltage - input signal too low Sensor A reference voltage - input signal too high Blink code of FI warning lamp (MIL) 27 FI warning lamp ( MIL ) flashes 2x long, 7x short Error le vel co ndition Senso[...]

22 FLASH CODE 170 Blink code of FI warning lamp (MIL) 45 FI warning lamp ( MIL ) flashes 4x long, 5x short Error le vel co ndition Lambda sensor heater - circuit fault Lambda sensor heater - short circuit to ground or open circuit Lambda sensor heater - input signal too high Blink code of FI warning lamp (MIL) 49 FI warning lamp ( MIL ) flashes 4x [...]

23 TECHNICA L DATA 171 23.1 Engine Design 1-cylinder 4-stroke engine, water-co oled Displacement 373 cm³ (22.76 cu in) Stroke 60 mm (2.36 in) Bore 89 mm (3.5 in) Compression ratio 12.6:1 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[...]

23 TECHNICA L DATA 172 4th gear 21:24 5th gear 23:22 6th gear 25:21 Mixture preparation Electronically controlled fuel injection Ignition Contactless controlled fully electro nic ignition with digital ignition adjustment Alternator 12 V, 296 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 e[...]

23 TECHNICA L DATA 173 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[...]

23 TECHNICA L DATA 174 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 20 Nm (14.8 lbf ft) Loctite ® 243™ Stu[...]

23 TECHNICA L DATA 175 23.3 Capacities 23.3.1 Engine oil Engine oil 1.6 l (1.7 qt.) Engine oil (SAE 15W/50) ( p. 184) 23.3.2 Coolant Coolant 1.1 l (1.2 qt.) Coolant ( p. 184) 23.3.3 Fuel Total fuel tank capacity, approx. 10 l (2.6 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 185) Fuel reserve, approx. 1.5 l (1.6 qt.) 23.4 Chassis Frame Lattic[...]

23 TECHNICA L DATA 176 Front 300 mm (11.81 in) Rear 230 mm (9.06 in) Brake discs - wear limit Front 4.5 mm (0.177 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) Rear 2.2 bar (32 psi) Secondary ratio 15:45 Chain 5/8 x 1/4” (520) O [...]

23 TECHNICA L DATA 177 23.5 Electrical system Battery ETZ-9-BS Bat tery voltage: 12 V Nominal capacity: 8 Ah Maintenance-free Fuse 75011088005 5 A Fuse 75011088010 10 A Fuse 75011088015 15 A Fuse 90111088025 25 A Fuse 75011088030 30 A Low beam H11 / Sockel PGJ19-2 12 V 55 W High beam H11 / Sockel PGJ19-2 12 V 55 W Parking light LED Instrument light[...]

23 TECHNICA L DATA 178 23.7 Fork Fork part number 90801000000 Fork WP Sus pension Fork length 736 mm (28.98 in) Fork oil 460 ml (15.55 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 185) 23.8 Shock absorber Shock absorber part number 90804010000 Shock absorber WP Suspension Spring preload Comfort 3 clicks Standard 5 clicks Sport 7 clicks Full payload [...]

23 TECHNICA L DATA 179 Screw, EFI control unit M4 3 Nm (2.2 lbf ft) – Nut, reflector on retaining plate M5 7 Nm (5.2 lbf ft) – Nut, retaining plate on license plate holder M5 4 Nm (3 lbf ft) – Remaining nuts, chassis M5 5 Nm (3.7 lbf ft) – Remaining screws, chassis M5 5 Nm (3.7 lbf ft) – Screw, ABS hose clamp M5 6 Nm (4.4 lbf ft) – Scre[...]

23 TECHNICA L DATA 180 Screw, ABS module on ABS module retaining bracket M6 7 Nm (5.2 lbf ft) – Screw, ABS module retaining bracket on silent block M6 7 Nm (5.2 lbf ft) – Screw, air filter box lid M6 3 Nm (2.2 lbf ft) – Screw, air filter box, on frame M6 6 Nm (4.4 lbf ft) – Screw, battery compartment M6 6 Nm (4.4 lbf ft) – Screw, brake fl[...]

23 TECHNICA L DATA 181 Screw, front spoiler retaining bracket, rear M6 6 Nm (4.4 lbf ft) – Screw, front spoiler retaining bracket, rear, on engine M6 9 Nm (6.6 lbf ft) – Screw, front spoiler, right, on footrest bracket M6 7 Nm (5.2 lbf ft) – Screw, ground cable, on frame M6 7 Nm (5.2 lbf ft) – Screw, handlebar stub M6 7 Nm (5.2 lbf ft) Loct[...]

23 TECHNICA L DATA 182 Screw, voltage regulator holder M6 11 Nm (8.1 lbf ft) – Screw, wheel speed sensor holder M6 9 Nm (6.6 lbf ft) Loctite ® 243™ Screw, windshield M6 9 Nm (6.6 lbf ft) – Nut, rear sprocket screw M8 27 Nm (19.9 lbf ft) – Remaining nuts, chassis M8 25 Nm (18.4 lbf ft) – Remaining screws, chassis M8 25 Nm (18.4 lbf ft) ?[...]

23 TECHNICA L DATA 183 Screw, front footrest bracket M10x1.25 50 Nm (36.9 lbf ft) – Screw, side stand bracket M10x1.25 3 3 Nm (24.3 lbf ft) Loctite ® 243™ Stud, rear sprocket M 10x1.25 50 Nm (36.9 lbf ft) – Nut, rear wheel spindle M14x1.5 90 Nm (66.4 lbf ft) – Screw, top steering head M16x1.5 52 Nm (38.4 lbf ft) Loctite ® 204™ Lambda se[...]

24 SUBSTAN CES 184 Brake fluid DOT 4 / DOT 5.1 Standard/classific ation – DOT Guideline – Use only brake fluid that compli es with the specified standard (see specifications on the container) and that exhibits the correspo nding properties. Recommended supplier Castrol – RES PONSE BRAKE FLUID SUPER DOT 4 Motorex ® – Brak e Flui d DOT 5.1 C[...]

24 SUBSTAN CES 185 Guideline – Use only engin e oils that comply with the specified standards (see specifications on the container) and that possess the correspo nding properties. Partially synthetic engine oil Recommended supplier Motorex ® – Form ula 4 T Fork oil (SAE 4) (48601166S1) Standard/classific ation – SAE ( p. 188) (SAE 4) Guideli[...]

25 AUXILIAR Y SUBSTANCES 186 Chain cleaner Recommended supplier Motorex ® – Cha in Clea n Chain lube for road use Guideline Recommended supplier Motorex ® – Cha inlube Road Fuel additive Recommended supplier Motorex ® – Fue l Stabi lizer Long-life grease Recommended supplier Motorex ® – Bike Grease 200 0 Motorcycle cleaner Recommended s[...]

25 AUXILIAR Y SUBSTANCES 187 Perfect Finish and high gloss polish for paints Recommended supplier Motorex ® – Mot o Polis h & Shine Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Mot o Prote ct Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ?[...]

26 STANDAR DS 188 JASO T903 MA Different technical developme nt directions required a new specification for 4-stroke motorcy cles – 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 189 INDEX A ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Antifreeze checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Antilock brake system . . . . . . . . . . . . . . . . . . . . . .[...]

INDEX 190 average fuel consumption 1/average fuel consumption 2 menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 average fuel consumption 2/servic e menu . . . . . . . . . . . . 48 average speed/average fuel consu mption 1 menu . . . . . . . 46 coolant temperature indicator . . . . . . . . . . . . . . . . . . . . . [...]

INDEX 191 Front rider's seat mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Front spoiler installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 removing . . . . . . . . . . . . . . . . . . . . . . . .[...]

INDEX 192 Oil scr eens cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Operating substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Owner's Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 P Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

INDEX 193 Steering locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]