KTM 2013 1190 Adventure R, Owner'S Manual

Page 1: ...OWNER S MANUAL 2013 1190 Adventure R EU 1190 Adventure R FR 1190 Adventure R AUS 1190 Adventure R JP Art no 3211956en ...

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Page 3: ... All specifications are non binding KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for delivery optio...

Page 4: ...According to the international quality management standard ISO 9001 KTM uses quality assurance processes that lead to the maximum possible quality of the products Issued by TÜV Management Service KTM Sportmotorcycle AG 5230 Mattighofen Austria ...

Page 5: ...l 20 5 3 Key number 21 5 4 Engine number 21 5 5 Fork part number 22 5 6 Shock absorber part number 22 6 CONTROLS 23 6 1 Clutch lever 23 6 2 Hand brake lever 23 6 3 Throttle grip 24 6 4 Switch on the left side of the handlebar 24 6 4 1 Combination switch 24 6 4 2 Light switch 25 6 4 3 Hazard warning flasher switch 25 6 4 4 Menu switch 26 6 4 5 Turn signal switch 26 6 4 6 Horn button 27 6 5 Switch o...

Page 6: ...e 53 7 9 18 Clock Date 54 7 9 19 Fuel Cons 54 7 9 20 DRL 55 7 9 21 Shift Light 55 7 9 22 Quick Shift 56 7 9 23 Heat Grips 56 8 ERGONOMICS 57 8 1 Handlebar position 57 8 2 Adjusting the handlebar position x 57 8 3 Adjusting the wind shield 58 8 4 Adjusting the basic setting of the clutch lever 60 8 5 Adjusting the basic position of the hand brake lever 60 8 6 Rider footrests 61 8 7 Adjusting the fo...

Page 7: ... 97 13 5 Checking for chain dirt 97 13 6 Cleaning the chain 98 13 7 Checking the chain tension 99 13 8 Adjusting the chain tension 100 13 9 Checking the chain rear sprocket and engine sprocket 102 13 10 Checking rectifying the fluid level of the hydraulic clutch 105 13 11 Checking the steering head bearing play 106 13 12 Removing the bottom triple clamp cover 107 13 13 Installing the bottom triple...

Page 8: ... 11 Checking the headlight setting 161 16 12 Adjusting the headlight range 162 17 COOLING SYSTEM 163 17 1 Checking the coolant level in the compensating tank 163 17 2 Correcting the coolant level in the compensating tank 164 18 ENGINE TUNING 166 18 1 Drive Mode 166 18 2 MTC motorcycle traction control 166 19 SERVICE WORK ON THE ENGINE 168 19 1 Checking the engine oil level 168 19 2 Changing the en...

Page 9: ...TABLE OF CONTENTS 7 24 SUBSTANCES 197 25 AUXILIARY SUBSTANCES 201 26 STANDARDS 204 INDEX 205 ...

Page 10: ...rstanding In the interest of your own safety have these jobs performed by an authorized KTM workshop There your motorcycle will be optimally cared for by specially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page 1 2 Formats used The typographical formats used in this document are explained below Specific name Identif...

Page 11: ...roads in the homologated version 2 2 Safety advice A number of safety instructions need to be followed to operate the vehicle safely Therefore read this manual carefully The safety instruc tions are highlighted in the text and are referred to at the relevant passages Info The vehicle has various information and warning labels at prominent locations Do not remove information warning labels If they ...

Page 12: ...ken Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken 2 4 Tampering warning Tampering with the noise control system is prohibited Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of desig...

Page 13: ...sness 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 Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch hot components such as exhaust system radiator engine shock absorber and the brake system Allow the...

Page 14: ...elf locking screws and nuts seals and seal rings O rings pins lock washers must be replaced by new parts Where thread lockers are used on screw connections e g Loctite follow the instructions for use from the manufacturer Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear Change damaged or worn parts Following repairs or servicing the veh...

Page 15: ...then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it as needed If you would like to know more about the vehicle or have questions on the material you read please contact an authorized KTM dealer The Owner s Manual is an important component of the vehicle ...

Page 16: ...auxiliary substances such as fuel and lubricants as specified in the Owner s Manual 3 3 Spare parts accessories For your own safety only use spare parts and accessory products that are approved and or recommended by KTM and have them installed by an authorized KTM workshop KTM accepts no liability for other products and any resulting damage or loss Certain spare parts and accessory products are sp...

Page 17: ...ese exactly you will ensure a much longer service life for your motorcycle 3 5 Figures The figures contained in the manual may depict special equipment In the interest of clarity some components may be shown disassembled or may not be shown at all It is not always necessary to disassem ble the component to perform the activity in question Please follow the instructions in the text 3 6 Customer ser...

Page 18: ...4 VIEW OF VEHICLE 16 4 1 View of vehicle front left side example S00318 10 ...

Page 19: ...p 29 2 Clutch lever p 23 3 Tool set p 34 4 Grab handles p 35 5 Luggage rack plate p 35 6 Seat lock p 34 7 Passenger footrests p 36 8 Center stand p 38 9 Rider footrests p 61 10 Shift lever p 36 11 Side stand p 37 12 Engine oil level viewer 13 Fuel cocks p 32 ...

Page 20: ...4 VIEW OF VEHICLE 18 4 2 View of vehicle rear right side example S00319 10 ...

Page 21: ... adjustment 4 Fork rebound adjustment 5 Emergency OFF switch p 27 6 Electric starter button p 28 7 Hand brake lever p 23 8 Storage compartment 9 Cooling system compensating tank 10 Foot brake lever p 63 11 Shock absorber compression adjustment 12 Shock absorber rebound adjustment ...

Page 22: ...7 10 The chassis number 1 is stamped on the bottom right of the frame behind the steering head The chassis number is also shown on the type label 5 2 Type label S00256 10 The type label 1 is on the top right of the frame behind the steering head ...

Page 23: ...to order a spare key Keep the KEYCODECARD in a safe place Use the orange programming key to activate and deactivate the black ignition key Keep the orange programming key in a safe place it must only be used for learning and programming functions 5 4 Engine number S00261 10 The engine number 1 is stamped on the right side of the engine ...

Page 24: ... 5 Fork part number S00306 10 The fork part number 1 is stamped on the inner side of the fork stub 5 6 Shock absorber part number S00264 10 The shock absorber part number 1 is stamped on the upper part of the shock absorber ...

Page 25: ...self adjusting 6 2 Hand brake lever S00215 10 The hand brake lever 1 is fitted on the right side of the handlebar The hand brake lever is used to activate both the front brake and rear brake at the same time Info When the Offroad ABS mode is switched on only the front brake is activated When ABS is switched off only the front brake is activated ...

Page 26: ... 6 4 Switch on the left side of the handlebar 6 4 1 Combination switch The combination switch is fitted on the left side of the handlebar S00224 10 Overview of the left combination switch 1 Light switch p 25 2 Hazard warning flasher switch p 25 3 Menu switch p 26 4 Turn signal switch p 26 5 Horn button p 27 ...

Page 27: ... 4 3 Hazard warning flasher switch 602606 10 The hazard warning flasher switch 1 is fitted on the combination switch on the left The hazard warning flasher is used to indicate emergency situations Info The hazard warning flasher can be activated or deactivated while the ignition is switched on or up to 60 seconds after the ignition is switched off Only keep the hazard warning flasher activated as ...

Page 28: ... signal switch S00217 10 The turn signal switch 1 is fitted on the combination switch on the left Possible states Turn signal off Press the turn signal switch 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 to the right The turn signal switch returns automatical...

Page 29: ...right side of the handlebar 6 5 1 Emergency OFF switch S00220 10 The emergency OFF switch 1 is fitted on the right side of the handlebar Possible states Emergency OFF switch off In this position the ignition circuit is interrupted a running engine stops and a non running engine cannot be started A message appears on the matrix display Emergency OFF switch on This position is required for operation...

Page 30: ...le clamp Info The ignition may only be switched on using a black ignition key With the orange programming key you can activate or deactivate the black ignition key Possible states Ignition off OFF In this position the ignition circuit is interrupted a run ning engine stops and a non running engine will not start The black igni tion key can be removed Ignition on ON In this position the ignition ci...

Page 31: ...Never attach multiple ignition keys to a single key ring this may cause mutual interference A lost black ignition key must be deactivated to prevent unauthorized persons from operat ing the vehicle The black ignition keys are activated when delivered Another two spare ignition keys key number on the KEYCODECARD can be ordered from an authorized KTM workshop they need to be activated for use 6 8 So...

Page 32: ... 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 Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep a...

Page 33: ...breakage To take pressure off of the ignition key push down on the filler cap Damaged igni tion keys must be replaced Turn ignition key 2 clockwise Fold open filler cap 3 6 10 Closing the filler cap S00228 10 Fold down filler cap 1 Turn ignition key 2 clockwise ...

Page 34: ...mediately clean contaminated areas on the skin with soap and water Remove ignition key 2 and close cover 3 6 11 Fuel cocks S00341 10 A fuel cock 1 is located on each side of the fuel tank Info The fuel cocks must always be open during operation The fuel cocks are only closed to remove the fuel tank Possible states Fuel cocks are closed A level equalization cannot take place and fuel cannot flow ou...

Page 35: ... Opening the storage compartment S00226 10 Press button 1 in the direction of the arrow and lift the cover at the same time 6 13 Closing the storage compartment S00226 11 Press down cover 1 until the lock engages audibly ...

Page 36: ... 14 Seat lock S00238 10 The seat lock 1 is located on the left side of the vehicle It can be unlocked using the ignition key 6 15 Tool set S00235 10 The tool set 1 is located in the storage compartment under the seat ...

Page 37: ... The luggage rack plate 1 is located behind the seat The base plate of a luggage system optional can be attached to the luggage rack plate The luggage rack plate may not be loaded with more than the specified weight Maximum permissible load on luggage rack plate 8 kg 18 lb Info Note the information provided by the luggage manufacturer ...

Page 38: ...footrests can be folded up and down Possible states Passenger footrests folded up For operation without a passenger Passenger footrests folded down For operation with a passenger 6 19 Shift lever S00231 10 The shift lever 1 is fitted on the left side of the engine ...

Page 39: ...ed for parking the motorcycle Info The side stand must be folded up during motorcycle use The side stand is coupled with the safety start system see the instructions in the Stopping parking chapter Possible states Side stand folded out The vehicle can be supported on the side stand The safety starting system is active Side stand folded in This position is mandatory when riding the motorcycle The s...

Page 40: ...6 CONTROLS 38 6 21 Center stand S00258 10 In addition to the side stand the vehicle is equipped with a center stand 1 ...

Page 41: ...strument is activated when the ignition is switched on Info The brightness of the displays is controlled by a brightness sensor in the combina tion instrument Test The segment display the indicator lamps and the tachometer are briefly activated for a function test The welcome text and information on the next service p 44 appear on the matrix dis play Info If the battery was disconnected the time a...

Page 42: ... If the General warning lamp lights up among the indicator lamps p 41 the corre sponding message appears in the matrix display The Set button is used to confirm receipt of the information and the message is cleared Messages appear 10 s 7 4 Segment display 401854 10 1 Fuel level 2 Time 3 Unit for the speedometer 4 Gear display 5 Speed 6 Drive Mode p 166 7 Coolant temperature 8 No function 9 Ice war...

Page 43: ...play The left turn signal lamp flashes green simultaneously with the turn signal The left turn signal is switched on The idle indicator lamp lights up green The transmission is shifted to idle The right turn signal lamp flashes green simultaneously with the turn signal The right turn signal is switched on The engine warning lamp lights up flashes yellow The engine control unit has detected a fault...

Page 44: ...ow Switch off the engine immediately Contact an authorized KTM workshop Engine oil level The engine oil level is too low Check the engine oil level and correct it Tire air pressure The tire pressure is incorrect or the system has failed Check the tire pressure Lighting system Lights up if an element of the lighting system has failed Change the faulty light or visit an authorized KTM workshop Cooli...

Page 45: ...in the Warnings menu 7 7 Shift warning light 401855 01 The shift warning light flashes or lights up when the transmission should be shifted In the Shift Light menu the engine speed for the shift warning light can be set The shift warning light flashes at RMP1 and lights up at RPM2 Engine oil temperature 35 C 95 F RPM1 shift warning light Flashes RPM2 shift warning light Lights up Engine oil temper...

Page 46: ...e found in the service schedule 7 9 Matrix display menu 7 9 1 Favorites 401827 01 Press the UP or DOWN button until the Favorites menu appears on the matrix display Pressing the SET button opens the menu Press the UP or DOWN button to select the menu item and activate it with the SET but ton Pressing the BACK button twice always opens the Favorites menu In the Favorites menu you can directly open ...

Page 47: ...e range with the fuel reserve Press and hold the button for 3 5 seconds All entries in the Trip 1 menu are cleared 7 9 3 Trip 2 401825 01 Press the UP or DOWN button until the Trip 2 menu appears on the matrix display Trip 2 shows the distance since the last reset such as between two refueling stops Trip 2 runs continuously and counts the distance up to 9999 Ø Speed 2 indicates the average speed b...

Page 48: ... the battery voltage Oil Temp indicates the engine oil temperature 7 9 5 TPMS optional 401845 01 Press the UP or DOWN button until the TPMS menu appears on the matrix display Guideline Tire air pressure solo with passenger full payload Front with cold tires 2 4 bar 35 psi Rear with cold tires 2 9 bar 42 psi The TPMS menu displays the tire pressure of the front and rear tires Front indicates the ti...

Page 49: ...OWN button to select the menu Press the SET button to set the menu for quick selection In the Set Favorites menu the Favorites menu can be configured 7 9 7 Settings 401841 01 Condition The vehicle is stationary Press the UP or DOWN button until the Settings menu appears on the matrix display Pressing the SET button opens the menu Setting for units or various values are made in the Settings menu So...

Page 50: ...on to navigate through the warnings In the Warnings menu warnings that occurred are displayed and stored until they are no longer active 7 9 9 Heat Grip optional 401838 01 Press the UP or DOWN button until the Heat Grip menu appears on the matrix display Pressing the SET button opens the menu Use the UP or DOWN button to navigate through the menu Use the SET button to select a heating level or to ...

Page 51: ...ivated ABS can intervene on both wheels 7 9 11 Drive Mode 401829 01 Press the UP or DOWN button until the Drive Mode menu appears on the matrix display Pressing the SET button opens the menu Use the UP or DOWN button to navigate through the menu The SET button can be used to select engine and traction control settings that are coordinated with each other SPORT homologated performance with very dir...

Page 52: ...7 COMBINATION INSTRUMENT 50 7 9 12 Menu overview 401849 01 ...

Page 53: ... messages are present Heat Grip optional MTC ABS Drive Mode 7 9 13 Language 401842 10 Condition The vehicle is stationary Press the UP or DOWN button until the Settings menu appears on the matrix display Pressing the SET button opens the menu Press the SET button again to select the language The menu languages are English German Italian French and Spanish ...

Page 54: ...e matrix dis play Pressing the SET button again sets the unit of measure Select kilometers km or miles mi for the distance 7 9 15 Temp 401842 12 Condition The vehicle is stationary Press the UP or DOWN button until the Settings menu appears on the matrix display Pressing the SET button opens the menu Press the UP or DOWN button until Temp is highlighted in black on the matrix display Pressing the ...

Page 55: ...play Pressing the SET button again sets the unit of measure Select liters or gallons for the fuel consumption display 7 9 17 Pressure 401842 14 Condition The vehicle is stationary Press the UP or DOWN button until the Settings menu appears on the matrix display Pressing the SET button opens the menu Press the UP or DOWN button until Pressure is highlighted in black on the matrix dis play Pressing ...

Page 56: ...he UP or DOWN button to navigate through the menu Use the SET button to set the time and date If the battery was disconnected the time and date must be set in the matrix display 7 9 19 Fuel Cons 401842 16 Condition The vehicle is stationary Press the UP or DOWN button until the Settings menu appears on the matrix display Pressing the SET button opens the menu Press the UP or DOWN button until Fuel...

Page 57: ...ime running light 7 9 21 Shift Light 401846 01 Condition The vehicle is stationary Press the UP or DOWN button until the Settings menu appears on the matrix display Pressing the SET button opens the menu Press the UP or DOWN button until Shift Light is highlighted in black on the matrix dis play Pressing the SET button again opens the menu Press the UP or DOWN button to select the function Use the...

Page 58: ... be activated Info This function is not available in this model 7 9 23 Heat Grips 401842 21 Condition The vehicle is stationary Press the UP or DOWN button until the Settings menu appears on the matrix display Pressing the SET button opens the menu Press the UP or DOWN button until Heat Grips is highlighted in black on the matrix dis play Pressing the SET button again switches the heat grips menu ...

Page 59: ...he handlebar position x Warning Danger of accidents Handlebar breakage If the handlebar is bent or straightened it will cause material fatigue and the handlebar can break Always replace handlebar 308080 01 Remove screws 1 Remove the handlebar clamps Remove the handlebar and lay it to one side Info Protect the motorcycle and its attachments against damage by covering them Do not bend the cables and...

Page 60: ...ebar supports evenly Position the handlebar Info Make sure cables and wiring are positioned correctly Position the handlebar clamps Mount and evenly tighten screws 1 Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft 8 3 Adjusting the wind shield S00342 10 Release clamping lever 1 by pulling in the direction of the arrow ...

Page 61: ...8 ERGONOMICS 59 S00247 10 Move the wind shield in the required position S00342 11 Lock clamping lever 1 by pushing in the direction of the arrow ...

Page 62: ...ew counterclockwise to decrease the distance between the clutch lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 8 5 Adjusting the basic position of the hand brake lever S00243 10 Adjust the basic position of the hand brake lever to your hand size by turning adjusting wheel 1 Info Pu...

Page 63: ... two positions Possible states Rider footrests low A Rider footrests high B 8 7 Adjusting the footrests x Info The operations are the same for the left and right sides S00248 10 Remove cotter pin 1 with washer 2 Remove pin 3 of the rider footrest Take off the rider footrest 4 with the spring ...

Page 64: ...ONOMICS 62 S00249 10 Remove screws 5 S00250 10 Adjust the footrest bracket to the desired position S00249 10 Mount and tighten screws 5 Guideline Screw front footrest bracket M8 25 Nm 18 4 lbf ft Loctite 243 ...

Page 65: ...d in front of the right footrest The rear brake is activated using the foot brake lever 8 9 Adjusting the basic position of the foot brake lever x Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to over heating Adjust the free travel on foot brake lever according to specific...

Page 66: ...dual requirements turn ball joint 4 accordingly Info The range of adjustment is limited The screw must be screwed into the ball joint by at least 5 turns Hold ball joint 4 and tighten nut 2 Guideline Remaining chassis nuts M6 10 Nm 7 4 lbf ft Mount and tighten screw 3 Guideline Remaining chassis nuts M6 10 Nm 7 4 lbf ft Attach spring 1 ...

Page 67: ... distance A between the upper edge of your boot and the shift lever Distance between shift lever and upper edge of boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the basic position of the shift lever x p 65 8 11 Adjusting the basic position of the shift lever x 101873 10 Remove screw 1 and take off shift lever 2 ...

Page 68: ...r on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle components during the shift procedure Mount and tighten the screw Guideline Screw shift lever M6 18 Nm 13 3 lbf ft Loctite 243 ...

Page 69: ...f crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the correspondi...

Page 70: ...andover Before your first trip read the entire Owner s Manual carefully Get to know the controls Adjust the motorcycle to your requirements as described in the Ergonomics chapter Get used to handling the motorcycle on a suitable piece of land before making a longer trip Try also to ride as slowly as possible and in a standing position to get a better feeling for the motorcycle Hold the handlebar f...

Page 71: ...ecure suitcase and tank rucksack according to the manufacturer s instructions Warning Danger of accidents Unstable handling characteristics at high speed Adapt your speed according to your payload Ride more slowly if your motorcycle is loaded with cases or other baggage Maximum speed with luggage 150 km h 93 2 mph Warning Danger of accidents Risk of breakage of suitcase system If you have fitted s...

Page 72: ... A hot exhaust system can burn baggage Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system If you are carrying baggage make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distri bution between the front and rear wheels Do not exceed the maximum permitted total weight and the axle loads Guideline Maximum pe...

Page 73: ... 126 Check the front brake linings p 126 Check the rear brake linings p 129 Check that the brake system is functioning properly Check the coolant level in the compensating tank p 163 Check the chain for dirt p 97 Check the chain tension p 99 Check the tire condition p 141 Check the tire air pressure p 142 Check the spoke tension p 143 Check the settings of all controls and ensure that they can be ...

Page 74: ...e damaged Never operate the vehicle with a discharged battery or without a battery Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always warm up the engine at low engine speeds 602607 01 Press the emergency OFF switch to the position ON Switch on the ignition by turning the black ignition key to the position ON After you switch on th...

Page 75: ...nsmission is in neutral or if the clutch lever is pulled when a gear is engaged If the side stand is folded out and you shift into gear the engine stops Remove the motorcycle from the center stand or side stand 10 3 Starting off Pull the clutch lever engage 1st gear release the clutch lever slowly and simultaneously open the throttle carefully 10 4 Shifting riding Warning Danger of accidents Abrup...

Page 76: ...g the minimum age of passengers Warning Danger of accidents Danger of accidents caused by dangerous driving Comply with traffic regulations and ride defensively and foresightedly to detect sources of danger early on Warning Danger of accidents Reduced road grip with cold tires On every journey take the first miles carefully at moderate speed until the tires reach operating temperature and optimal ...

Page 77: ...ehicle as usual before preparing for use Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear Note Engine failure Overheating of engine If the coolant temperature warning lamp lights up stop and switch off the engine Allow the engine to ...

Page 78: ...t 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 and open the throttle or shift again If the engine stalls e g at a crossroads just pull the clutch lever and press the elec tric starter button You do not have to shift into neutral Switch off the engine if you ex...

Page 79: ...m and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Failure of brake system If the foot brake lever is not released the brake linings drag continuously The rear brake may fail due to overheating Take your foot off the foot brake lever when you are not braking Warning Danger of accidents Longer stopping distance due to higher overall weight Tak...

Page 80: ...he road condi tions and your riding ability When braking release the throttle and apply the front and rear brakes at the same time Info When ABS is enabled you can achieve maximum braking power even on low grip surfaces such as sandy wet or slippery ter rain without locking of the wheels Warning Danger of accidents Locking of the wheels due to braking action of the engine Pull the clutch during em...

Page 81: ...uch as exhaust system radiator engine shock absorber and the brake system Allow these components to cool down before starting work on them Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Note Fire hazard Some vehicle components become very hot when the vehicle is operated Do not park the vehicle near flammable or explosive sub...

Page 82: ...ed on at the ignition lock power continues to flow to most power consumers This discharges the battery You should therefore always switch off the engine with the ignition key the emergency OFF switch is intended for emergencies only Park the motorcycle on a firm surface Alternative 1 Swing the side stand forward with your foot as far as it will go and lean the vehicle on it Alternative 2 Raise the...

Page 83: ...ear 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 immediately The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin...

Page 84: ...help 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 S00239 10 Switch off the engine Open the filler cap p 30 Fill the fuel tank with fuel up to the lower edge A of the filler neck Total fuel tank capacity approx 23 l 6 ...

Page 85: ...000 km 620 mi Read out the trouble code memory using the KTM diagnostics tool x Check the fuel pressure x Check the functioning of the electrical equipment Change the engine oil and filter clean the oil screens x p 169 Check the brake discs p 122 Check the front brake linings p 126 Check the rear brake linings p 129 Retighten the spokes x Check the spoke tension p 143 Check the rim run out x Check...

Page 86: ...ension p 99 Check the brake lines for damage and leakage Check the brake fluid level of the front brake p 123 Check the coolant level in the compensating tank p 163 Change the air filter Clean the air filter box x Check the cables for damage and routing without sharp bends fuel tank removed x Change the spark plugs air filter removed x Check the valve clearance air filter and spark plugs removed x...

Page 87: ...t setting p 161 Final check Check the vehicle for roadworthiness and take a test ride Read out the error memory after the test ride using the KTM diagnostics tool x Check the CO adjustment with the KTM diagnostics tool x Make the service entry in the KTM DEALER NET and in the Service and Warranty Booklet x One time interval Periodic interval ...

Page 88: ...aring for play x Grease all moving parts e g side stand hand lever chain and check for smooth operation x Check all hoses e g fuel cooling bleeder drainage etc and sleeves for cracking leaks and incorrect routing x Check the antifreeze x Check rectify the fluid level of the hydraulic clutch p 105 Change the hydraulic clutch fluid x Check the screws and nuts for tightness x Change the coolant x One...

Page 89: ...guidelines are not adhered to the riding characteristics could deteriorate particularly at high speeds 12 2 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior S00262 10 Turn the white adjusting screw 1 all the way clockwise Info Adjusting screw 1 is located at the upper end of the left fork leg The compression damping is loc...

Page 90: ...fork Info The hydraulic rebound damping determines the fork suspension behavior S00263 10 Turn the red adjusting screw 1 all the way clockwise Info Adjusting screw 1 is located at the upper end of the right fork leg The rebound damping is located in the right fork leg REB red adjusting screw The compression damping is located in the left fork leg COMP white adjusting screw Turn counterclockwise by...

Page 91: ... counterclockwise to reduce damping 12 4 Adjusting the spring preload of the fork S00260 10 Turn adjusting screws 1 counterclockwise all the way Info Make the same adjustment on both fork legs Turn clockwise by the number of turns corresponding to the fork type Guideline Spring preload Preload Adjuster Comfort 2 turns Standard 5 turns Sport 5 turns Full payload 8 turns ...

Page 92: ...when riding over an asphalt edge the rear wheel suspension compresses quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses more slowly These two ranges can be adjusted separately although the transition between high speed and low speed is gradual Thus changes in the high speed range affect the compression damping in the lo...

Page 93: ...clicks Sport 8 clicks Full payload 8 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 12 7 Adjusting the high speed compression damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will...

Page 94: ...ping high speed Comfort 1 5 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce damping 12 8 Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your a...

Page 95: ... 15 clicks Standard 10 clicks Sport 8 clicks Full payload 8 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 12 9 Adjusting the spring preload of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM worksh...

Page 96: ...go Turn it clockwise by the number of turns corresponding to the shock absorber type and use Guideline Spring preload Comfort 4 turns Standard 4 turns Sport 4 turns Full payload 16 turns Info Turn clockwise to increase the spring preload turn counterclockwise to reduce the spring preload ...

Page 97: ...nter stand The center stand or the frame may become damaged and the motorcycle may fall over Pull the motorcycle up onto the center stand at the grab handles S00307 10 Stand to the left of the vehicle Hold the handlebar with your left hand and push the center stand onto the ground with your right foot Put your entire weight on arm 1 of the center stand while pulling the vehicle up at the left grab...

Page 98: ...he vehicle tips off of the center stand activate the front brake to stop the vehi cle from rolling away Check that the center stand is folded all the way up 13 3 Removing the seat S00241 10 Insert the ignition key in seat lock 1 and turn it clockwise by 45 Lift up the seat at the rear pull it back and lift off Remove the ignition key ...

Page 99: ...lower the rear while pushing it forward Insert locking pin 2 into the lock housing and push down the rear of the seat until the locking pin engages with a click Check that the seat is correctly mounted 13 5 Checking for chain dirt 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 98 ...

Page 100: ...and grease and clean them with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations 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 ...

Page 101: ... cases If the chain is too loose however it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine Ensure that the chain tension is correct and adjust it if necessary 401664 10 Place the motorcycle onto the side stand Shift the transmission to idle In the area in front of the chain guide push the chain up and determine chain ten sion A Info The upper part o...

Page 102: ... bearings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme cases If the chain is too loose however it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine Ensure that the chain tension is correct and adjust it if necess...

Page 103: ... and right chain adjusters 4 are in the same position in relation to reference marks C The rear wheel is then correctly aligned Info The upper part of the chain must be taut Chain wear is not always even so you should check the setting at different chain positions Tighten nuts 2 Make sure that chain adjusters 4 are resting against adjusting screws 3 Tighten nut 1 Guideline Nut rear wheel spindle M...

Page 104: ...et Preparatory work Raise the vehicle with the center stand p 95 100132 10 Main work Check the rear sprocket and engine sprocket for wear If the rear sprocket or engine sprocket is worn Change the power set x Info The rear sprocket engine sprocket and chain should always be changed together ...

Page 105: ...in section Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance B at the longest chain section 272 mm 10 71 in If distance B is greater than the specified measurement Change the power set x Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out faster on old worn sprockets F...

Page 106: ...liding guard Change the chain sliding guard x Check the chain sliding guard for tightness If the chain sliding guard is loose Tighten the chain sliding guard Guideline Screw chain sliding guard M5 5 Nm 3 7 lbf ft 401670 01 Check the chain guide for wear If the chain guide is worn Change the chain guide x Check the chain guide for tightness If the chain guide is loose Tighten the chain guide ...

Page 107: ...sing wear of the clutch lining disc Do not use brake fluid S00270 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 Check the fluid level Fluid level below top edge of container 4 mm 0 16 in If the coolant level does not meet specifications Correct the fluid level of the hydraulic clutch Hydraulic fluid 15 p 199 Posi...

Page 108: ...work Raise the vehicle with the center stand p 95 400738 11 Main work Place a load on the rear of the vehicle The front wheel is not in contact with the ground Move the handlebar to the straight ahead position Move the fork legs back and forth in the direction of travel Play should not be detectable on the steering head bearing If there is no detectable play Adjust the steering head bearing play x...

Page 109: ...ving the bottom triple clamp cover 202248 12 Remove screws 1 Plug out the horn Remove the triple clamp cover 2 13 13 Installing the bottom triple clamp cover x 202248 13 Position the triple clamp cover 1 Plug in the horn Mount and tighten screws 2 Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft ...

Page 110: ...13 SERVICE WORK ON THE CHASSIS 108 13 14 Removing the front side cover 307815 10 Remove screw 1 307816 10 Remove screws 2 Remove side cover 3 Repeat the operation on the opposite side ...

Page 111: ...E CHASSIS 109 13 15 Installing the front side cover 307817 10 Position the side cover in the A area under the tank cover 307818 10 Attach catch 1 and bracket 2 of the side cover to the fuel tank and position the side cover ...

Page 112: ...part M5x12 3 5 Nm 2 58 lbf ft 307816 11 Mount and tighten screws 4 Guideline Screw cover part M5x12 3 5 Nm 2 58 lbf ft Repeat the operation on the opposite side 13 16 Removing the mask spoiler x Preparatory work Remove the seat p 96 Remove the front side cover p 108 Remove the tank cover p 116 ...

Page 113: ...13 SERVICE WORK ON THE CHASSIS 111 307823 10 Main work Remove screw 1 307824 10 Remove screw 2 307825 10 Loosen holding lug 3 from the inside cover ...

Page 114: ...12 307828 10 Remove the mask spoiler laterally from the supports 307826 10 Pull the mask spoiler upward from bracket 4 307827 10 Detach connector 5 Remove the mask spoiler with the turn signal Repeat the operation on the opposite side ...

Page 115: ...CE WORK ON THE CHASSIS 113 13 17 Installing the mask spoiler x 307827 11 Main work Plug in connector 1 307826 11 Position the mask spoiler in bracket 2 Info Ensure that the turn signal cable is placed correctly ...

Page 116: ...N THE CHASSIS 114 307828 11 Press the mask spoiler laterally into the supports 307825 10 Position holding lug 3 in the drill hole 307824 11 Mount and tighten screw 4 Guideline Screw mask spoiler M5x17 3 5 Nm 2 58 lbf ft ...

Page 117: ...bf ft Repeat the operation on the opposite side Finishing work Install the tank cover p 118 Install the front side cover p 109 Mount the seat p 97 13 18 Removing the front fender S00323 10 Remove holder 1 from the front fender Remove screws 2 Remove the fender in a forward direction Info Pay attention to the brake lines ...

Page 118: ...tion to where the brake lines are placed Mount and tighten screws 1 Guideline Screw fender M5x12 3 5 Nm 2 58 lbf ft Mount holder 2 with the brake line on the fender 13 20 Removing the tank cover Preparatory work Remove the seat p 96 Remove the front side cover p 108 307819 10 Main work Remove screw 1 Remove screw 2 ...

Page 119: ...13 SERVICE WORK ON THE CHASSIS 117 307820 10 Remove screw 3 Remove screw 4 307821 10 Remove screw 5 307822 10 Raise the tank cover at the rear and remove it in a forward direction ...

Page 120: ... Position the tank cover Info Note the sealing lip Mount and tighten screw 1 Guideline Screw cover part M5x12 3 5 Nm 2 58 lbf ft 307820 11 Mount and tighten screw 2 Guideline Screw cover part M6 6 Nm 4 4 lbf ft Mount and tighten screw 3 Guideline Screw cover part M5x12 3 5 Nm 2 58 lbf ft ...

Page 121: ...4 Guideline Screw cover part M6 6 Nm 4 4 lbf ft Mount and tighten screw 5 Guideline Screw cover part M5x12 3 5 Nm 2 58 lbf ft Finishing work Install the front side cover p 109 Mount the seat p 97 13 22 Removing the wind shield S00259 10 Remove screws 1 and wind shield 2 ...

Page 122: ...13 SERVICE WORK ON THE CHASSIS 120 13 23 Installing the wind shield S00259 11 Position wind shield 1 Mount and tighten screws 2 Guideline Screw wind shield M5 3 5 Nm 2 58 lbf ft ...

Page 123: ...BS is only ensured if the brake system only contains spare parts and tires that have been approved and or recommended by KTM Service work and repairs must be performed properly Your authorized KTM workshop will be glad to help The ABS is a safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces Warning Danger of accidents Vehicle rollov...

Page 124: ...lit 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 system itself stays functional only ABS control is not available The ABS lamp may also light up if the rotating speeds of the front and rear wheels differ greatly under extreme riding conditions for example when making wheelies or if the rear wheel sp...

Page 125: ...ge cracking and deformation If the brake disc exhibits damage cracking or deformation Change the brake disc 14 3 Checking the brake fluid level of the front brake 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 autho...

Page 126: ... out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and co...

Page 127: ...brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Preparatory work Check the front brake linings p 126 S00272 10 Main work 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 the MAX mark A Brake fluid DOT 4 DOT 5 ...

Page 128: ... the brake linings regularly S00305 10 Check all brake linings on both brake calipers to ensure they have minimum thick ness A Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the front brake linings x Check all brake linings on both brake calipers for damage and cracking If there is damage or cracking Change the front brake linings x 14 6 Checking the rear bra...

Page 129: ...center stand p 95 S00273 10 Main work Check the brake fluid level in the brake fluid reservoir 1 If the fluid level reaches the MIN marking A Add rear brake fluid x p 127 14 7 Adding rear 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 syste...

Page 130: ...d rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designe...

Page 131: ...ar brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help Note Danger of accidents Reduced braking 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 greatl...

Page 132: ...nings for minimum thickness A Minimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings x Check the brake linings for damage and cracking If there is wear or tearing Change the rear brake linings x ...

Page 133: ...n contact with the ground Remove screw 1 and pull wheel speed sensor 2 out of the hole S00314 10 Remove screws 3 from both brake calipers Press back the brake linings with a light lateral tilting of the brake calipers on the brake disc Pull the brake calipers carefully back from the brake discs and hang them to one side Info Do not pull the hand brake lever when the brake caliper has been removed ...

Page 134: ...amp Remove screw 4 Warning Danger of accidents Reduced braking efficiency due to damaged brake discs Always lay down the wheel in such a way that the brake discs are not dam aged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork Info Do not pull the hand brake lever when the front wheel is removed S00316 10 Remove spacers 6 ...

Page 135: ...g for damage and wear If the wheel bearing is damaged or worn Change the wheel bearing x Clean and grease the shaft seal rings 1 and contact surface A of the spacers Long life grease p 202 S00339 10 Insert the wide spacer 2 on the left in the direction of travel Info The arrow B indicates the direction of travel of the front wheel The ABS sensor wheel is on the left hand side when looking in the d...

Page 136: ...e Screw front wheel spindle M25x1 5 45 Nm 33 2 lbf ft S00314 11 Position the brake calipers and check that the brake linings are seated correctly Mount screws 5 on both brake calipers but do not tighten yet Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Fix the hand brake lever in the activated posi tion The brake ca...

Page 137: ...hassis screws M6 10 Nm 7 4 lbf ft Remove the vehicle from the center stand p 95 S00315 11 Pull the front brake and compress the fork forcefully a few times The fork legs straighten Tighten screws 8 Guideline Screw fork stub M8 15 Nm 11 1 lbf ft 15 3 Removing the rear wheel x Preparatory work Raise the vehicle with the center stand p 95 ...

Page 138: ...5 10 Main work Press the brake caliper by hand on to the brake disc in order to press back the brake pistons S00277 10 Remove screw 1 and pull wheel speed sensor 2 out of the hole S00276 10 Remove nut 3 Remove chain adjuster 4 ...

Page 139: ...he rear wheel withdraw the wheel spindle Take the rear wheel out of the swing arm Info Do not operate the foot brake when the rear wheel is removed Remove the spacer 7 15 4 Installing the rear wheel x Warning Danger of accidents Reduced braking 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 Warn...

Page 140: ... life grease p 202 Clean and grease the thread of the wheel spindle and nut Long life grease p 202 Mount the rubber dampers and rear sprocket carrier in the rear wheel Place the rear wheel in the swingarm and bring the brake disc on the brake caliper into contact S00287 10 Mount wheel spindle 2 but do not push it in all the way Push the rear wheel as far forward as possible and place the chain on ...

Page 141: ...reference marks B Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Thread greased S00289 10 Insert wheel speed sensor 6 into the hole Mount and tighten screw 7 Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point 15 5 Checking the rear hub rubber dampers x Info The eng...

Page 142: ...ed or worn Change all rubber dampers in the rear hub S00291 10 Lay the rear wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub Check the rear sprocket play A Info Measure the play on the outside of the rear sprocket Play in rubber dampers rear wheel 5 mm 0 2 in If clearance A larger than the specified value Change all rubber dampers in the rear hub F...

Page 143: ...ontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Warning Danger of accidents Reduced road grip with new tires New tires have a smooth rolling surface and therefore cannot provide full road grip The entire rolling surface must be rough ened in the first 200 kilometers 1...

Page 144: ...tires Info The tire s date of manufacture is usually part of the tire markings and is indi cated by the last four digits of the DOT marking The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture KTM recommends that the tires be changed after 5 years at the latest regard less of the actual state of wear If a tire is more than five years old Change...

Page 145: ...rrect the tire pressure Mount the dust cap 15 8 Checking spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that the spoke tension is correct Your authorized KTM workshop will be glad to help Info A loose spoke can easily cause lateral or radial runout on the wheel More spokes loosen in a short period If the spokes are too tight they can break due to ...

Page 146: ...he frequency of the sound is a function of the spoke length and spoke diame ter If spokes of the same length and diameter vibrate with a different tone this is an indication that the spoke tensions differ You should hear a high note If the spoke tension differs Correct the spoke tension x ...

Page 147: ...nfo Note the legal regulations regarding the daytime running light 16 2 Removing the battery x Warning Risk of injury Battery acid and battery gases cause serious chemical 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 battery Only charge in well ventilated r...

Page 148: ...he engine Remove the seat p 96 S00302 10 Main work Pull locking mechanism 1 in the direction of the arrow Fold open cover 2 S00303 10 Disconnect negative cable 3 of the battery Disconnect the positive cable 4 of the battery Take the battery and battery case 5 out of the battery compartment ...

Page 149: ...ts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic components and safety equipment may be damaged Never operate the vehicle with a discharged battery or without a battery 602677 10 Main work Insert the battery into battery case ...

Page 150: ...arning Risk of injury Battery acid and battery gases cause serious chemical 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 battery Only charge in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the ...

Page 151: ...the battery Rapid recharging with a high charging current shortens the battery s service life If the charging current charging voltage and charging time are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for a...

Page 152: ...cle s electronics 602678 01 Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 You can also use the battery charger to test the open circuit voltage and start potential of the battery and to test the alternator With this device you cannot overcharge the battery Info Charge the battery with a maximum of 10 of the capacity specified on the bat tery h...

Page 153: ...e and charging time must not be exceeded Charge the battery regularly when the motorcycle is not in use 3 months 602677 11 Connect both negative cables 3 Guideline Screw battery terminal M6 4 5 Nm 3 32 lbf ft S00304 10 Fold down cover 4 and let it lock by pushing down lightly Finishing work Mount the seat p 97 Set the time and date ...

Page 154: ...erloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 96 S00332 10 Main work Remove screws 1 Raise rear fairing 2 slightly S00311 10 Remove protection caps 3 ...

Page 155: ... consumers of the vehicle Install a new main fuse Fuse 58011109130 p 190 Check that the electrical equipment is functioning properly Mount protection covers Tip Insert a new spare fuse into the starter relay to have it available when needed S00332 10 Position rear fairing 2 Mount and tighten screws 1 Guideline Screw cover part M5x12 3 5 Nm 2 58 lbf ft Finishing work Mount the seat p 97 Set the tim...

Page 156: ...the wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Info The fuse box containing the fuses of individual power consumers is located under the seat Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 96 S00322 10 Main work Open fuse box cover 1 ...

Page 157: ...trol units and components Fuse 2 10 A socket ACC1 Fuse 3 25 A ABS hydraulic unit Fuse 4 40 A ABS return pump Fuse 5 not used Use spare fuses with the correct rating only Fuse 58011109110 p 189 Fuse 58011109125 p 190 Fuse 58011109140 p 190 Tip Insert a spare fuse so that it is available if needed Check that the power consumer is functioning properly Close the fuse box cover Finishing work Mount the...

Page 158: ... off the engine Remove the seat p 96 Remove the front side cover p 108 Remove the tank cover p 116 Remove the mask spoiler x p 110 Remove the wind shield p 119 S00293 10 Main work Remove screws 1 Remove the headlight mask forward S00294 10 Disconnect plug 2 Place the headlight mask onto a soft cloth so that the headlight is not damaged ...

Page 159: ...e lighting is functioning properly Position the headlight mask S00293 11 Mount and tighten screws 2 Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft Finishing work Install the wind shield p 120 Install the mask spoiler x p 113 Install the tank cover p 118 Install the front side cover p 109 Mount the seat p 97 Check the headlight setting p 161 ...

Page 160: ... before mounting Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 96 Remove the front side cover p 108 Remove the tank cover p 116 Remove the mask spoiler x p 110 Remove the wind shield p 119 Remove the headlight mask with the headlight p 156 S00297 10 Main work Push headlight bulb 1 lightly into the bulb socket turn it all the way counterclockwise and pu...

Page 161: ...he headlight p 157 Install the wind shield p 120 Install the mask spoiler x p 113 Install the tank cover p 118 Install the front side cover p 109 Mount the seat p 97 Check the headlight setting p 161 16 10 Changing the high beam bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of gre...

Page 162: ...k Push headlight bulb 1 lightly into the bulb socket turn it all the way counterclockwise and pull it out Disconnect plug 2 S00296 10 Plug connector 2 into the new headlight bulb High beam H11 socket PGJ19 2 p 190 Position headlight bulb 1 into the bulb socket and turn it all the way clockwise The headlight bulb is locked into the bulb socket Finishing work Refit the headlight mask with the headli...

Page 163: ...k at a distance B under the first mark Guideline Distance B 5 cm 2 in Position the vehicle perpendicular to the wall at a distance A from the wall and switch on the low beam Guideline Distance A 5 m 16 ft The rider with luggage and passenger if applicable now mounts the motorcycle Check the headlight setting The light dark boundary must lie exactly on the lower mark when the motorcycle is ready to...

Page 164: ...kwise to increase the headlight range turn counterclockwise to reduce the headlight range If you have a payload you may have to correct the headlight range 400726 11 Set the headlight to marking B Guideline The light dark boundary must lie exactly on the lower mark B when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applicable Finishing work I...

Page 165: ...with the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swallowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Condition The engine is cold The radiator is completely full S00324 10 Park the motorcycle on a horizontal surface Chec...

Page 166: ...water Warning Danger of poisoning Coolant is poisonous 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 contaminated areas on the skin with soap and water If coolant is swallowed contact a physician immediately Change clothing that is contaminated with coolan...

Page 167: ...326 01 Add coolant until the coolant reaches the specified level Guideline The coolant level must be between MIN and MAX Alternative 1 Coolant p 197 Alternative 2 Coolant mixed ready to use p 197 Mount the cover of the compensating tank Finishing work Install the front side cover p 109 ...

Page 168: ...e menu You can choose from SPORT STREET RAIN and OFFROAD The drive mode selected last is displayed on the right in the segment display Info The drive mode selection has no influence on the ABS 18 2 MTC motorcycle traction control 401837 01 The traction control lowers the tightening torque in case of loss of traction in the rear wheel Depending on the traction control setting a slight slip on the r...

Page 169: ...18 ENGINE TUNING 167 Info When traction control is active the TC lamp flashes When traction control is switched off the TC lamp is lit ...

Page 170: ...ck the engine oil level in the engine oil level viewer Info After switching off the engine wait one minute before checking the level The engine oil level should be in the upper area B of the engine oil level viewer When the engine oil level is in area A of the engine oil level viewer Do not add engine oil When the engine oil level is in area B of the engine oil level viewer Engine oil can be added...

Page 171: ...urns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Preparatory work Remove the engine guard x S00333 10 Main work Stand the motorcycle on its side stand on a horizontal surface Place a suitable container under the engine...

Page 172: ...with the O ring S00335 10 Pull oil filter 4 out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing surface S00336 10 Insert oil filter 4 Lubricate the O ring of the oil filter cover Mount the oil filter cover 3 ...

Page 173: ...s 2 Guideline Remaining engine screws M5 6 Nm 4 4 lbf ft 100773 12 Thoroughly clean magnet A and oil screen B of the oil drain plugs S00333 10 Mount and tighten oil drain plugs 1 with the magnet O rings and oil screen Guideline Oil drain plug M20x1 5 20 Nm 14 8 lbf ft ...

Page 174: ...pprox 3 0 l 3 2 qt Outside temperature 0 C 32 F Engine oil SAE 10W 50 p 198 Outside temperature 0 C 32 F Engine oil SAE 5W 40 p 198 Mount screw plug 5 Danger Danger of poisoning Exhaust gases 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 ...

Page 175: ...n and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight Finishing work Check the engine oil level p 168 Install the engine guard x 19 3 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the engine The engine may be damaged if the engine oil level is to...

Page 176: ...n the engine oil level viewer Condition Outside temperature 0 C 32 F Engine oil SAE 10W 50 p 198 Condition Outside temperature 0 C 32 F Engine oil SAE 5W 40 p 198 Info In order to achieve optimal engine performance it is not advisable to mix differ ent engine oils KTM recommends changing the engine oil Mount the screw plug ...

Page 177: ...esult 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 Start the engine and check that it is oil tight Finishing work Check the engine oil level p 168 ...

Page 178: ...ke fluid etc should be disposed of as stipulated in applicable regulations Info If you clean the motorcycle regularly its value and appearance will be maintained over a long period Avoid direct sunshine on the motorcycle during cleaning 401061 01 Close off the exhaust system to keep water from entering First remove coarse dirt particles with a gentle spray of water Spray very dirty areas with a no...

Page 179: ...orate Push back the protection caps of the handlebar controls to allow any water that has penetrated to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 98 Treat bare metal parts except for brake discs and exhaust system with corrosion inhibitor Cleaning and preserving materials for metal rubber and plastic p 201 Treat the painted parts with a...

Page 180: ...e motorcycle p 176 Clean the brakes Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts are cooled down and while they are installed After riding on salted roads thoroughly wash the motorcycle with cold water and dry it well Treat the engine the swingarm and all other bare or galvanized par...

Page 181: ... refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 201 Clean the motorcycle p 176 Change the engine oil and filter clean the oil screens x p 169 Check the coolant fill level and antifreeze x Check the tire air pressure p 142 Remove the battery x p 145 Guideline Storage temperature of battery without direct sunshine 0 35 C 32 95 F Recharge the...

Page 182: ...water vapor produced during combustion condenses and causes valves and the exhaust system to rust 21 2 Preparing for use after storage 401059 01 Remove the vehicle from the center stand p 95 Recharge the battery x p 148 Install the battery x p 147 Info If the battery was disconnected the time and date must be set Refuel p 81 Perform checks and maintenance measures when preparing for use p 71 Take ...

Page 183: ...Recharge the battery x p 148 Check the quiescent current x Safety start system is faulty Read out the fault memory using the KTM diag nostics tool x ICU is not enabled Activate the ICU x CAN bus communication error Read out the fault memory using the KTM diag nostics tool x Fault in EFI control unit Read out the fault memory using the KTM diag nostics tool x Fault in MCU control unit Read out the ...

Page 184: ...s up ABS fuse is blown Change the fuses in the fuse box p 154 Wheel speeds of front and rear wheels differ greatly Stop switch off the ignition start again Malfunction in ABS Read out the fault memory using the KTM diag nostics tool x High oil consumption Engine oil level too high Check the engine oil level p 168 Engine oil too thin low viscosity Change the engine oil and filter clean the oil scre...

Page 185: ...haust 34 mm 1 34 in Valve clearance Exhaust at 20 C 68 F 0 25 0 30 mm 0 0098 0 0118 in Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Crankshaft bearing Sleeve bearing Conrod bearing Sleeve bearing Piston Forged light alloy Piston ring 1 upper compression rectangular ring 1 lower compression ring 1 oil scraper ring Engine lubrication Dry sump lubrication system with three rotor pumps Primary tr...

Page 186: ...spark plug NGK LMAR7A 9 Electrode gap spark plug 0 8 0 9 mm 0 031 0 035 in Cooling Water cooling permanent circulation of coolant by water pump Cold start device Electric starter 23 2 Engine tightening torques Screw retaining bracket valve cover rear EJOT Altracs M6x10 10 Nm 7 4 lbf ft Hose clip intake flange M4 1 5 Nm 1 11 lbf ft Remaining engine screws M5 6 Nm 4 4 lbf ft Screw bearing retainer M...

Page 187: ...rew clutch spring M6 12 Nm 8 9 lbf ft Screw coolant connection on cylinder head M6 10 Nm 7 4 lbf ft Screw damping plate M6 10 Nm 7 4 lbf ft Loctite 243 Screw engine case M6x60 10 Nm 7 4 lbf ft Screw engine case M6x80 10 Nm 7 4 lbf ft Screw engine case M6x90 10 Nm 7 4 lbf ft Screw freewheel holder M6 10 Nm 7 4 lbf ft Loctite 243 Screw locking lever M6 10 Nm 7 4 lbf ft Loctite 243 Screw oil pump cov...

Page 188: ... 1 10 Nm 7 4 lbf ft Step 2 18 Nm 13 3 lbf ft Screw engine case M8 18 Nm 13 3 lbf ft Screw engine console M8 20 Nm 14 8 lbf ft Loctite 243 Screw timing chain guide rail M8 15 Nm 11 1 lbf ft Loctite 243 Screw timing chain tensioning rail M8 15 Nm 11 1 lbf ft Loctite 243 Stud exhaust flange M8 10 Nm 7 4 lbf ft Oil pressure sensor M10x1 10 Nm 7 4 lbf ft Plug cam lever axis M10x1 15 Nm 11 1 lbf ft Plug...

Page 189: ...1 5 90 Nm 66 4 lbf ft Spark plug M12x1 5 15 Nm 11 1 lbf ft Nut of engine sprocket M20x1 5 100 Nm 73 8 lbf ft Loctite 243 Oil drain plug M20x1 5 20 Nm 14 8 lbf ft Nut inner clutch hub M22x1 5 130 Nm 95 9 lbf ft Loctite 243 Plug timing chain tensioner M24x1 5 25 Nm 18 4 lbf ft Screw in alternator cover M24x1 5 8 Nm 5 9 lbf ft Nut primary gear M33LHx1 5 130 Nm 95 9 lbf ft Loctite 243 23 3 Capacities ...

Page 190: ... ROZ 95 RON 95 PON 91 p 199 Fuel reserve approx 3 5 l 3 7 qt 23 4 Chassis Frame Lattice frame made of chrome molybdenum steel tubing powder coated Fork WP Suspension 4860 MXTA SPLIT Shock absorber WP Suspension 4618 BAVP DCC PA Suspension travel Front 220 mm 8 66 in Rear 220 mm 8 66 in Brake system Front Double disc brake with radially mounted four pot brake calipers floating brake discs Rear Sing...

Page 191: ...drive ratio 17 42 Chain 5 8 x 5 16 525 X ring Steering head angle 64 Wheelbase 1 580 mm 62 2 in Seat height unloaded 890 mm 35 04 in Ground clearance unloaded 250 mm 9 84 in Weight without fuel approx 217 kg 478 lb Maximum permissible front axle load 159 kg 351 lb Maximum permissible rear axle load 281 kg 619 lb Maximum permissible total weight 440 kg 970 lb 23 5 Electrical system Battery YTZ14S B...

Page 192: ...indicator lamps LED Turn signal LED Tail light LED Brake light LED License plate lamp LED 23 6 Tires Front tires Rear tires 90 90 V 21 M C 54V TL Continental ContiTrailATTACK 2 150 70 ZR 18 M C 70W TL Continental ContiTrailATTACK 2 Additional information is available in the Service section under http www ktm com 23 7 Fork Fork part number 14 18 8M 25 Fork WP Suspension 4860 MXTA SPLIT Compression ...

Page 193: ...ll payload 7 clicks Spring preload Preload Adjuster Comfort 2 turns Standard 5 turns Sport 5 turns Full payload 8 turns Spring length with preload spacer s 475 mm 18 7 in Spring rate Medium standard 5 5 N mm 31 4 lb in Fork length 915 mm 36 02 in Air chamber length 95 25 15 mm 3 74 0 98 0 59 in Fork oil per fork leg 720 ml 24 34 fl oz Fork oil SAE 4 48601166S1 p 199 ...

Page 194: ...omfort 15 clicks Standard 10 clicks Sport 8 clicks Full payload 8 clicks Compression damping high speed Comfort 1 5 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Rebound damping Comfort 15 clicks Standard 10 clicks Sport 8 clicks Full payload 8 clicks Spring preload Comfort 4 turns Standard 4 turns Sport 4 turns Full payload 16 turns Spring rate ...

Page 195: ... screws chassis M5 5 Nm 3 7 lbf ft Screw brake line holder on swingarm M5 5 Nm 3 7 lbf ft Screw cable channel M5 5 Nm 3 7 lbf ft Screw cable guide wheel speed sensor rear M5 3 Nm 2 2 lbf ft Screw chain sliding guard M5 5 Nm 3 7 lbf ft Screw combination switch right M5 3 5 Nm 2 58 lbf ft Screw cover part M5x12 3 5 Nm 2 58 lbf ft Screw filler cap M5 5 Nm 3 7 lbf ft Screw foot brake lever stub M5 6 N...

Page 196: ... Nm 3 7 lbf ft Screw cooler retaining bracket M6 7 Nm 5 2 lbf ft Screw cover part M6 6 Nm 4 4 lbf ft Screw engine guard M6 10 Nm 7 4 lbf ft Screw foot brake cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw front brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw fuel pump M6 6 Nm 4 4 lbf ft Screw fuel tank M6 10 Nm 7 4 lbf ft Screw fuel tap M6 6 Nm 4 4 lbf ft Screw lower rear part M6 6 Nm 4 4 lbf ft ...

Page 197: ... M8 25 Nm 18 4 lbf ft Loctite 243 Screw rear footrest bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw steering damper clamp M8 12 Nm 8 9 lbf ft Screw suitcase hook M8 20 Nm 14 8 lbf ft Screw top triple clamp M8 15 Nm 11 1 lbf ft Engine carrying screw M10 45 Nm 33 2 lbf ft Remaining chassis nuts M10 45 Nm 33 2 lbf ft Remaining chassis screws M10 45 Nm 33 2 lbf ft Screw front brake caliper M10 45 Nm ...

Page 198: ... greased Screw top shock absorber M14x1 5 80 Nm 59 lbf ft Thread greased Nut socket M18x1 4 Nm 3 lbf ft Nut swingarm pivot M19x1 5 130 Nm 95 9 lbf ft Thread greased Screw steering head top M22x1 5 50 Nm 36 9 lbf ft Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Thread greased Screw front wheel spindle M25x1 5 45 Nm 33 2 lbf ft Nut steering head top M28x1 0 12 Nm 8 9 lbf ft ...

Page 199: ...ex products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant also in countries with high temperatures Use of low quality antifreeze can lead to corrosion and foaming KTM recommends Motorex products Mixture ratio Antifreeze protection 25 45 C 13 49 F 50 corrosion inhibitor antifreeze 50 distilled water Coolant mixed ready to u...

Page 200: ...orresponding properties KTM recommends Motorex products Fully synthetic engine oil Supplier Motorex Power Synt 4T Engine oil SAE 5W 40 According to JASO T903 MA p 204 SAE p 204 SAE 5W 40 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties KTM recommends Motorex products Synthetic engine oil Suppli...

Page 201: ...il that complies with the specified standard see specifications on the container and that possesses the corre sponding properties KTM recommends Motorex products Supplier Motorex Hydraulic Fluid 75 Shock absorber oil SAE 2 5 50180342S1 According to SAE p 204 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that possess the correspondi...

Page 202: ...eaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 ...

Page 203: ...n lube for road use Guideline KTM recommends Motorex products Supplier Motorex Chainlube Road Cleaning and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Supplier Motorex Protect Shine Fuel additive Guideline KTM recommends Motorex products Supplier Motorex Fuel Stabilizer ...

Page 204: ... grease Guideline KTM recommends Motorex products Supplier Motorex Bike Grease 2000 Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean Polish ...

Page 205: ...25 AUXILIARY SUBSTANCES 203 Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Synthetic ...

Page 206: ...rvice intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Stan dard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils...

Page 207: ... linings front brake checking 126 rear brake checking 129 Brake system 121 130 Brakes 77 Brakes applying 77 C Capacity coolant 188 engine oil 172 187 188 fuel 82 188 Center stand 38 Chain checking 102 checking for dirt 97 cleaning 98 Chain tension adjusting 100 checking 99 Chassis number 20 Clutch fluid level checking rectifying 105 Clutch lever 23 adjusting 60 Combination instrument 39 56 ABS 49 ...

Page 208: ...5 Temp 52 TPMS 46 Trip 1 45 Trip 2 45 Volume 53 Warnings 48 Combination switch 24 Overview 24 Coolant level compensating tank checking 163 compensating tank correcting 164 Customer service 15 E Electric starter button 28 Emergency OFF switch 27 Engine running in 68 Engine number 21 Engine oil adding 173 changing 169 Engine oil level checking 168 Engine sprocket checking 102 Environment 12 F Figure...

Page 209: ...ion adjusting 60 Handlebar position 57 adjusting 57 Hazard warning flasher 25 Hazard warning flasher switch 25 Headlight daytime running light 145 headlight range adjusting 162 Headlight mask with headlight installing 157 removing 156 Headlight setting checking 161 High beam bulb changing 159 Horn button 27 I Ignition lock 28 immobilizer 29 Intended use 9 K Key number 21 L Light switch 25 Low beam...

Page 210: ...ures when preparing for use 71 Protective clothing 12 R Rear hub rubber dampers checking 139 Rear sprocket checking 102 Rear wheel installing 137 removing 135 Refueling fuel 81 Rider footrests 61 Riding 73 starting off 73 S Safe operation 11 Seat mounting 97 removing 96 Seat lock 34 Service 14 Service schedule 83 86 Shift lever 36 basic position adjusting 65 basic position checking 65 Shifting 73 ...

Page 211: ...t Closing 33 Opening 33 Suspension setting 87 94 Switch on the left side of the handlebar 24 on the right side of the handlebar 27 T Tank cover installing 118 removing 116 Technical data capacities 187 chassis 188 chassis tightening torques 193 electrical system 189 engine 183 196 engine tightening torques 184 fork 190 shock absorber 192 tires 190 Throttle grip 24 Tire air pressure checking 142 Ti...

Page 212: ...raising with the center stand 95 removing from the center stand 95 View of vehicle front left side 16 rear right side 18 W Warranty 14 Wind shield adjusting 58 installing 120 removing 119 Winter operation checks and maintenance steps 178 Work rules 12 ...

Page 213: ... 3211956en 3211956en 07 2013 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...