KTM 990 SupermotoR, Owner'S Manual

Page 1: ...OWNER S MANUAL 2011 990 Supermoto R USA Art no 3211661en ...

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Page 3: ...o print However it is never possible to exclude small deviations arising from further development in design and construction 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 con...

Page 4: ...ds is permitted only with the express written permission of the copyright owner ISO 9001 12 100 6061 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: ... buttons 36 Combination instrument tachometer 36 Combination instrument indicator lamps 37 Combination instrument display 38 Combination instrument speedometer 39 Setting kilometers or miles 39 Combination instrument time 40 Setting the clock 40 Combination instrument ODO display 41 Combination instrument setting resetting TRIP 1 41 Combination instrument setting resetting TRIP 2 42 Combination in...

Page 6: ...ear wheel stand 80 Taking the motorcycle off of the rear wheel stand 80 Bleeding the fork legs 81 Removing the seat 81 Mounting the seat 82 Mounting the helmet lock on the vehicle 82 Reinstalling the fuel tank 83 Positioning the fuel tank 84 Checking the chain for dirt 86 Cleaning the chain 86 Checking the chain tension 87 Adjusting the chain tension 88 Checking the chain rear sprocket and engine ...

Page 7: ...8 TUNING THE ENGINE 151 Checking the play in the throttle cable 151 Adjusting the play in the throttle cable x 152 Ignition curve plug in connector 152 Adjusting the ignition curve to the fuel quality 153 Checking the basic position of the shift lever 153 Adjusting the basic position of the shift lever x 154 SERVICE WORK ON THE ENGINE 155 Checking the engine oil level 155 Changing the engine oil a...

Page 8: ...TABLE OF CONTENTS 6 TECHNICAL DATA CHASSIS TIGHTENING TORQUES 191 SUBSTANCES 194 AUXILIARY SUBSTANCES 198 STANDARDS 200 INDEX 201 ...

Page 9: ...tanding In the interest of your own safety have these jobs performed by an authorized KTM workshop There your motorcycle will be serviced opti mally by specially trained experts using the specialist tools required Identifies a page reference more information is provided on the specified page Formats used The typographical formats used in this document are explained below Specific name Identifies a...

Page 10: ...wet roads can lead to above average wear of components such as the transmission train or the brakes For this reason it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached Pay careful attention to the prescribed running in period and service intervals Close adherence to these periods will significantly lengthen the service life of your mot...

Page 11: ...eses Ex valve spring mounter 59029019000 During assembly non reusable parts e g self 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 da...

Page 12: ...rful sport and we naturally hope that you can enjoy it to the full However it can also lead to problems with the environment and conflict with other persons Responsible behavior in handling the motorcycle can help to avoid such problems and con flicts To protect the future of motorcycle sport make sure that you use your motorcycle legally display environmental consciousness and respect the rights ...

Page 13: ...IMPORTANT INFORMATION 11 ...

Page 14: ...IMPORTANT INFORMATION 12 2 1 Overview of labels 601101 10 ...

Page 15: ...Information on operating substances and tires 4 Information on noise emission 5 Information on preparing for use 6 Information on the fuel evaporation system 7 Information on chain tension 7 Information on suspension setting 8 Type label USA 101177 01 Information on emission control ...

Page 16: ...IMPORTANT INFORMATION 14 600962 01 Type label Canada 600969 01 Information on operating substances and tires ...

Page 17: ...IMPORTANT INFORMATION 15 101178 01 Information on noise emission 600961 01 Information on preparing for use ...

Page 18: ...IMPORTANT INFORMATION 16 101179 01 Information on the fuel evaporation system 600966 01 Information on chain tension 600967 01 Information on suspension setting ...

Page 19: ...rnings Pay close attention to the notes warnings Info Various information and warning labels are affixed to the vehicle Do not remove information warning labels If they are missing you or others may not recognize potential hazards and may therefore be injured ...

Page 20: ...ins useful information and tips to help you operate and handle your motorcycle Only then will you find out how to best customize the motorcycle for your own use and how you can protect yourself from injury The owner s manual also contains important information on servicing the motorcycle The owner s manual is an important component of the motorcycle and should be handed over to the new owner if th...

Page 21: ...runo QC J3V 6B7 Phone 450 441 4451 x 4250 www ktmcanada com Tampering warning It is not permitted to make changes to the components of the noise damping system Federal law prohibits the following acts or causing thereof 1 The removal or rendering inoperative other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur...

Page 22: ...to the applicable laws and regulations Consumer rights Warranty claims should be submitted to an authorized KTM workshop If you are not satisfied please contact KTM North America Inc Customer Support 1119 Milan Ave Amherst OH 44001 USA Phone 440 985 3553 www ktmusa com KTM Canada Inc Customer Support 1375 1 Marie Victorin Saint Bruno QC J3V 6B7 Phone 450 441 4451 x 4250 www ktmcanada com Your righ...

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Page 24: ...VIEW OF VEHICLE 22 3 1 View of vehicle front left side vehicle differs slightly from photo 101091 10 ...

Page 25: ...HICLE 23 1 Combination instrument p 35 2 Rear mirror 3 Clutch lever p 30 4 Seat 5 Handrails p 47 6 Level viewer engine oil 7 Shift lever p 49 8 Engine number p 28 9 Compression damping of the shock absorber p 74 ...

Page 26: ...VIEW OF VEHICLE 24 3 2 View of vehicle rear right side vehicle differs slightly from photo 101092 10 ...

Page 27: ...2 Horn button p 33 3 Filler cap 4 Emergency OFF switch p 34 4 Electric starter button p 35 5 Hand brake lever p 30 6 Fork rebound setting and spring preload setting 7 Shock absorber rebound adjustment 8 Passenger footrests p 49 9 Foot brake lever p 50 10 Chassis number type label p 26 11 Fork compression adjustment ...

Page 28: ...SERIAL NUMBERS 26 4 1 Chassis number type label 101093 10 Chassis number is embossed in the steering head at the right 601116 10 The type label for the USA is fitted on the frame tube on the right ...

Page 29: ...e number 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 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 ...

Page 30: ... 28 4 3 Engine number 101095 10 The engine number is stamped on the left side of the engine under the engine sprocket 4 4 Fork part number 101096 10 The fork part number is stamped on the inner side of the fork stub ...

Page 31: ...SERIAL NUMBERS 29 4 5 Shock absorber part number 101097 10 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side ...

Page 32: ...ver is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 5 2 Hand brake lever 101099 10 The hand brake lever is fitted on the right side of the handlebar The front brake is engaged using the hand brake lever ...

Page 33: ... switch 700550 10 The light switch is fitted on the left side of the handlebar Possible states Low beam on The light switch is turned downwards 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 high beam and tail light are switched on ...

Page 34: ...ignal switch 700550 11 The turn signal switch is fitted on the left side of the handlebar Possible states Turn signal off Left turn signal on The turn signal switch is pressed to the left The turn signal switch automatically returns to the central position after use Right turn signal on The turn signal switch is pressed to the right The turn signal switch automatically returns to the central posit...

Page 35: ...may only be switched on using a black ignition key Use the orange programming key to activate and deactivate the black ignition key Possible states Ignition OFF In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start The ignition key can be removed Ignition ON In this position the ignition circuit is closed and the engine can be started S...

Page 36: ...d lead to problems A lost black ignition key must be deactivated to prevent unauthorized persons from operat ing the vehicle The second black ignition key is activated when the vehicle is shipped Two additional spare ignition keys key number on the KEYCODECARD can be ordered from an authorized KTM workshop but they must be activated before use 5 10 Emergency OFF switch 700552 10 The emergency OFF ...

Page 37: ... Electric starter button in basic position Electric starter button pressed The electric starter is actuated in this position 5 12 Combination instrument 400920 10 The combination instrument is installed in front of the handlebar The combination instrument is divided into 4 function areas Function buttons Tachometer Indicator lights Display ...

Page 38: ...O trip master 1 TRIP 1 trip mas ter 2 TRIP 2 and the ambient temperature Press the SET button to reset the trip master 1 function TRIP 1 and trip master 2 func tion TRIP 2 to 0 0 Button has no function 5 14 Combination instrument tachometer 400922 10 The tachometer shows the engine speed in revolutions per minute The red marking shows the excess speed range of the engine ...

Page 39: ... beam is switched on The temperature warning lamp lights up red The coolant temperature has reached a critical value The fuel level warning lamp lights up orange The fuel level has reached the reserve mark The display switches to TRIP F The oil pressure warning lamp lights up red The oil pressure is too low Warning lamp FI MIL lights up flashes orange The OBD on board diag nosis has detected an em...

Page 40: ...ments light up for one second as a function test 400837 01 LEnGth Following the display function test the LEnGth wheel circumference is shown for one sec ond Info 1870 mm corresponds to the circumference of the 17 front wheel with a series pro duction tire The display then changes to the last selected mode ...

Page 41: ...e speed is shown in kilometers per hour km h or in miles per hour mph 5 18 Setting kilometers or miles Info If you change the unit the value ODO is retained and converted accordingly Making the setting according to the country Condition The motorcycle is stationary ...

Page 42: ...O mode is active Keep the MODE button pressed until the display mode changes from km h to mph or from mph to km h 5 19 Combination instrument time 400893 11 The time is shown in area of the display Info After reconnecting the battery or changing the fuse the time must be reset 5 20 Setting the clock Condition The motorcycle is stationary ...

Page 43: ...utton pressed simultaneously The time is set 5 21 Combination instrument ODO display 400839 01 In the ODO display mode the total distance traveled is shown in kilometers or miles Info This value is retained even if the battery is disconnected and or the fuse blows 5 22 Combination instrument setting resetting TRIP 1 Info The TRIP 1 trip counter is always running and counts up to 999 9 The trip cou...

Page 44: ...ing TRIP 2 Info The TRIP 2 trip counter is always running and counts up to 999 9 The trip counter can be used to measure the distance covered during trips or between two refueling stops After the value 999 9 is reached the trip counter starts at 0 0 again 400841 01 Switch on the ignition by turning the ignition key to the ON position Press the MODE button repeatedly until the TRIP 2 mode is active...

Page 45: ...mark the display automatically changes to TRIP F and starts to count from 0 0 regardless of the previous display mode Info The low fuel warning lamp lights up in parallel to the TRIP F display 5 25 Combination instrument ambient temperature display 400893 13 The ambient temperature is displayed in C or F ...

Page 46: ...tton pressed until the display mode changes from C to F or from F to C 5 27 Combination instrument warning of slippery roads 400894 10 The ice symbol lights up to indicate an increased danger of slippery roads The ice symbol appears in the display when the ambient temperature drops below the specified value Temperature 3 C 37 F The ice symbol goes out in the display when the ambient temperature ri...

Page 47: ... 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 Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel ...

Page 48: ...e ignition key Note Danger of damage Ignition key breakage To take pressure off of the ignition key push down on the filler cap Damaged igni tion keys must be replaced Turn the ignition key 90 counterclockwise and remove the filler cap Info The filler cap has a tank air vent system 5 30 Closing the filler cap 101102 01 Put the filler cap back on and turn the ignition key 90 clockwise Remove the ig...

Page 49: ...ails are used for moving the motorcycle around If you carry a passenger the passenger can hold onto the handrails during the trip 5 32 Seat lock 101104 10 Seat lock is located at the rear under the tail light It can be locked with the ignition key ...

Page 50: ...dents Impairment of ride behavior and vehicle operation if a helmet or helmet lock is attached to the vehicle Do not use the helmet lock for holding a helmet or other objects during the jour ney Always remove the helmet lock before starting out The steel cable in the tool set can be used to lock a helmet to the vehicle to prevent it from being stolen ...

Page 51: ...r 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 5 36 Shift lever 101108 10 Shift lever is mounted on the left side of the engine ...

Page 52: ... can be seen in the photograph The neutral or idle position is between the first and second gear 5 37 Foot brake lever 101110 10 Foot brake lever is located in front of the right footrest The rear brake is activated using the foot brake lever ...

Page 53: ... The side stand must be folded up during motorcycle use Side stand is coupled with the safety start system see the riding instructions Possible states Side stand folded out The vehicle can be leaned on the side stand The safety start system is active Side stand folded in This position is mandatory for all trips The safety start system is inactive ...

Page 54: ...nt 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 corresponding speed index should be used Warning Danger of...

Page 55: ...ly as possible to get a better feeling for the motorcycle Hold the handlebar firmly with both hands and keep your feet on the footrests when riding Run the engine in p 53 6 2 Running in the engine Do not exceed the specified engine speed and load during the running in period Guideline Maximum engine speed During the first 1 000 km 621 4 mi 6 500 rpm After the first 1 000 km 621 4 mi 9 500 rpm Avoi...

Page 56: ...ses note the manufacturer s specifications concerning the maximum payload Warning Danger of accidents Poor visibility for other road users due to slipped baggage If the tail light is covered you are less visible to traffic behind you especially in the dark Check that your baggage is fixed properly at regular intervals Warning Danger of accidents Changed handling characteristics and longer stopping...

Page 57: ...r of the vehicle and ensure even weight distri bution between the front and rear wheels Do not exceed the maximum permissible total weight and the axle loads Guideline Maximum permissible total weight 400 kg 882 lb Maximum permissible front axle load 160 kg 353 lb Maximum permissible rear axle load 250 kg 551 lb ...

Page 58: ...evel p 100 Check the front brake linings p 97 Check the rear brake linings p 102 Check that the brake system is functioning properly Check the coolant level in the compensating tank p 145 Check the chain for dirt p 86 Check the chain tension p 87 Check the tire condition p 110 Check the tire air pressure p 112 Check that all controls are correctly adjusted and free to move Check that the electrica...

Page 59: ... in an enclosed space without an effective exhaust extraction system 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 Note Engine failure High engine speeds in cold engines have a negative effect on the service life ...

Page 60: ...tarting DO NOT open the throttle If you open the throttle during the start ing procedure fuel is not injected by the engine management system and the engine cannot start Press the starter for a maximum of 5 seconds Wait for a least 5 seconds before trying again This motorcycle is equipped with a safety start system You can only start the engine if the transmission is in neutral or if the clutch is...

Page 61: ...gnition key position Do not change the ignition key position during a journey Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle Make all adjustments when the vehicle is at a standstill Warning Risk of injury The passenger must be able to sit securely on the passenger seat The passenger must hold on to the rider or supporting strap firmly and place his her ...

Page 62: ...e tires have been run in Warning Danger of accidents Unstable handling characteristics Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational and with a full tank driver and passenger with protective clothing and helmet baggage Warning Danger of accidents Unstable handling characteristics due to slipped baggage Check the way your baggage is ...

Page 63: ...ch and open the throttle Info You can see the positions of the six forward gears in the figure The neutral or idle position is between the first and second gears First gear is used for starting off or for steep inclines After reaching maximum speed by fully opening the throttle grip turn the throttle back so it is open This will barely reduce the speed but fuel consumption will be consid erably lo...

Page 64: ...Danger of accidents If you brake too hard the wheels can lock Adapt your braking to the traffic situation and the road conditions Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake Check the brake ...

Page 65: ...nd Shift down to a lower gear that is appropriate to your speed On long downhill stretches use the braking effect of the engine Do this by changing down two gears but do not race the engine You will require less braking force and the brakes will not overheat 7 6 Stopping parking Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secur...

Page 66: ...e brakes Shift the transmission to neutral Switch off the ignition by turning the ignition key to the OFF position Info If you switch off the engine with the emergency OFF switch but the ignition remains switched on at the ignition lock power continues to flow to most power consumers and the battery is soon discharged Therefore always switch off the engine with the ignition key the emergency OFF s...

Page 67: ...doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc tor immediately Change clothing that has come into contact with fuel Note Material damage Premature clogging of the fuel filter In some countries and regions the available fuel quality and cleanliness may not be sufficient This will result in problems with the fuel system Your authorized KTM workshop...

Page 68: ...mage Low quality fuel damages the engine Operate the vehicle with fuel with an octane rating below 95 ROZ 95 RON 95 PON 91 for no more than one tank full The ignition curve must be adjusted to low octane fuel Adjust the ignition curve to the fuel quality p 153 400970 12 Press the SET button for two seconds The fuel level warning lamp switches off TRIP F is set to 0 0 and appears in the previous di...

Page 69: ...k the rear brake linings p 102 Check the rear brake disc p 99 Check that brake lines are undamaged and free of leaks Check the rear brake fluid level p 100 Check the free travel of the foot brake lever p 98 Check the shock absorber and fork for leaks Perform a fork and shock absorber service if needed and depending on vehicle use Check the swingarm bearings x Check the wheel bearing for play x Che...

Page 70: ...ss of the throttle valve body for damage and correct routing x Check the cables for damage and kink free routing x Check the control cables for damage kink free routing and adjustment Change the air filter Clean the air filter box x Check the fuel pressure x Check the value of the manifold absolute pressure sensor PM value with the KTM diagnostics tool x Check the CO adjustment with the KTM diagno...

Page 71: ...oadworthiness and take a test ride Read out the fault memory after a test ride using the KTM diagnostics tool x Make the service entries in the KTM DEALER NET and service record x K10N Once after 1 000 km 621 4 mi K75A Every 7 500 km 4 660 mi or annually K150A Every 15 000 km 9 321 mi or every 2 years K300A Every 30 000 km 18 641 mi or every 4 years ...

Page 72: ...n the adjusting screws against the stop and take the last perceptible click as the end position These adjustments should be understood as a guideline and should always be the basis of your own personal suspension adaptation Do not change the adjustments at random or by more than 40 since otherwise the riding characteristics could deteriorate particularly at high speeds 9 2 Adjusting the compressio...

Page 73: ... the fork type Guideline Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 9 3 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork rebound behavior An optimally adjusted rebound damping brakes the springing energy and enables a f...

Page 74: ...amping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase suspension damping turn counterclockwise to reduce damping 9 4 Adjusting the spring preload of the fork Info The spring preload defines the initial situation of the spring process of the fork The spring preload setting is optimal when it is set for the weight of the rider and that of ...

Page 75: ... corresponding to the fork type Guideline Spring preload Preload Adjuster Comfort 5 turns Standard 5 turns Sport 3 turns Full payload 3 turns Info Turn clockwise to increase preload turn counterclockwise to reduce spring preload Changing the spring preload has no influence on the rebound damping although the adjusting screws turn during the adjustment work However you should also adjust the reboun...

Page 76: ...ver 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 low speed range and vice versa 9 6 Adjusting the low speed compression damping of the shock absorber Caution Danger of accidents Disassembly ...

Page 77: ...cks Sport 15 clicks Full payload 15 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 9 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 b...

Page 78: ...ing high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce damping 9 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 autho...

Page 79: ...e shock absorber x Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle s ride behavior Following modifications ride slowly at first to get the feel of the new ride behavior Info The spring preload defines the initial situation of the spring process on the shock absorber The spring preload setting is optimal when it is set for the weight of the rider...

Page 80: ...d of weight 101122 10 Loosen locking ring Turn adjusting ring until the spring is no longer under tension Hook wrench T106S Measure the overall spring length without a load Tension the spring by turning adjusting ring to the prescribed value Guideline Spring preload Comfort 11 mm 0 43 in Standard 11 mm 0 43 in Sport 11 mm 0 43 in Full payload 13 mm 0 51 in Tighten locking ring ...

Page 81: ... the handlebar to the straight ahead position Align the front wheel stand with the fork legs using the adapters Front wheel stand 61029055300 Info Always raise the rear of the motorcycle first Raise the front of the motorcycle 10 2 Taking the motorcycle off of the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surfa...

Page 82: ...l stand Adapter 61029055120 Rear wheel stand 61029055100 Stand the motorcycle upright align the wheel stand with the link fork and the adapters and lift the motorcycle 10 4 Taking the motorcycle off of the rear wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Secure the motorcycle against falling over Remove the rea...

Page 83: ...ss pressure escapes from the interior of the fork Mount and tighten the bleeder screws Info Carry out this operation on both fork legs 10 6 Removing the seat 101104 10 Insert the ignition key in the seat lock and turn it clockwise Raise the rear of the seat push it towards the rear and remove it upwards Remove the ignition key from the seat lock ...

Page 84: ...t lock on the vehicle Warning Danger of accidents Impairment of ride behavior and vehicle operation if a helmet or helmet lock is attached to the vehicle Do not use the helmet lock for holding a helmet or other objects during the journey Always remove the helmet lock before start ing out 101140 10 Remove the seat p 81 Position the steel cable from the tool set with one loop on the lug Steel cable ...

Page 85: ... ON THE CHASSIS 83 10 9 Reinstalling the fuel tank Remove the seat p 81 101163 10 Remove screws and the spoiler on both sides 101164 10 Remove screw on both sides Info The fuel hoses do not need to be disconnected ...

Page 86: ...165 10 Remove screw Carefully push the fuel tank back 10 10 Positioning the fuel tank Carefully push the fuel tank forward 101165 11 Mount and tighten screw with the collar bushing Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft ...

Page 87: ...nd rubber sleeve on both sides Check the fuel tank for tightness Guideline Remaining chassis screws M8 25 Nm 18 4 lbf ft Check the routing of the fuel lines 101163 11 Position the spoilers on both sides Mount and tighten screws Guideline Screw spoiler M6 3 3 Nm 2 43 lbf ft Mount the seat p 82 ...

Page 88: ...ces their grip Remove oil and grease with a suitable cleaning material 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 Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should b...

Page 89: ...ng Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bearings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On the other hand if the chain is loose it...

Page 90: ...just the chain tension p 88 10 14 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bearings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of th...

Page 91: ...nce marks The rear wheel is then correctly aligned Info The upper chain section must be taut Chain wear is not always even so you should check the setting at different chain positions Tighten nuts Make sure that chain adjusters are resting against adjusting screws Tighten nut Guideline Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Thread greased Info The wide adjustment range of the chain adjus...

Page 92: ...ocket and engine sprocket 100132 10 Check the rear sprocket and engine sprocket for wear If the rear sprocket or engine sprocket is worn Replace the rear sprocket or engine sprocket x Info The rear sprocket engine sprocket and chain should always be changed together ...

Page 93: ... section Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance at the longest chain section 272 mm 10 71 in If distance is greater than the specified measurement Replace the chain 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 For safety...

Page 94: ...ard M5 5 Nm 3 7 lbf ft Screw chain sliding guard M6 6 Nm 4 4 lbf ft Loctite 243 10 16 Adjusting the basic position of the clutch lever Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar The range of adjustment is limited Turn the adj...

Page 95: ... of the clutch lining disc Do not use brake fluid 101167 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane 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 196 Position the cover ...

Page 96: ... brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc s Change the worn brake disc s without delay Your authorized KTM workshop will be glad to help 100135 10 Check the thickness of the brake disc in several places to see if it conforms to measure ment Info Wear reduces the thickness of the brake discs in area of the brake discs Brake discs wear limit Front 4 5...

Page 97: ...ystem or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help 101175 10 Move the brake fluid reservoir mounted on the ...

Page 98: ...he eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid ...

Page 99: ...homologation documents Info Brake linings available in accessories shops are often untested and unapproved for use on KTM vehicles The structure and friction coefficient of the brake linings and therefore the brake power can vary considerably from the original KTM brake linings If brake linings other than those supplied as originals are used there is no guarantee that they correspond to the origin...

Page 100: ...y have minimum thick ness 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 damage or wear is encountered Change the front brake linings x 11 7 Checking the free travel of the foot brake lever Warning Danger of accidents Brake system failure If there is no free tr...

Page 101: ...d value 11 8 Checking the rear brake disc Warning Danger of accidents Reduced braking efficiency due to worn brake disc s Change the worn brake disc s without delay Your authorized KTM workshop will be glad to help 400480 10 Check the thickness of the brake disc in several places to see if it conforms to measure ment Info Wear reduces the thickness of the brake disc in area of the brake disc Brake...

Page 102: ...kage 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 Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help 101126 10 Stand the vehicle upright C...

Page 103: ...the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid...

Page 104: ...n the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid immediately with water 11 11 Checking the rear 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 ...

Page 105: ...he braking effect is greatly reduced and the brake discs are rendered unserviceable Check the brake linings regularly 101129 10 Check the brake linings for minimum thickness Minimum thickness 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 damage or wear is encountered Change the rear brake linings x ...

Page 106: ...fully back from the brake discs and hang them to one side Info Do not pull the hand brake lever when the brake calipers are removed 101131 10 Loosen screws and Unscrew screw about six turns and press your hand on the screw to push the wheel spindle out of the axle clamp Remove screw Warning Danger of accidents Reduced braking efficiency caused by damaged brake discs Always lay the wheel down in su...

Page 107: ...ake cleaner when necessary 101132 10 Check the wheel bearing for damage and wear If the wheel bearing is broken or worn Replace the wheel bearing x Grease and mount the left and right spacers and the shaft seal rings Long life grease p 199 Clean screw and wheel spindle Lift the front wheel into the fork position it and insert the wheel spindle Mount and tighten screw Guideline Bolt front axle M25x...

Page 108: ...hand brake lever in its engaged posi tion The brake calipers straighten Tighten screws on both brake calipers Guideline Screw front brake caliper M10x1 25 45 Nm 33 2 lbf ft Loctite 243 Remove the fixation of the hand brake lever Take the motorcycle off of the front wheel stand p 79 Take the motorcycle off of the rear wheel stand p 80 101131 11 Pull the front brake and compress the fork powerfully ...

Page 109: ...ible and take the chain off the rear sprocket Withdraw the wheel spindle Pull the rear wheel backward until the brake caliper support hangs free between the brake disc and the wheel rim Warning Danger of accidents Reduced braking efficiency caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not dam aged Take the rear wheel carefully out of the swingarm w...

Page 110: ...alling the rear wheel always operate the foot brake until the pressure point is reached Check the rear hub shock absorbers x p 109 101135 10 Check the wheel bearing for damage and wear If the wheel bearing is broken or worn Replace the wheel bearing x Remove spacer Clean and grease the mating surfaces of the spacers and the shaft seal rings Long life grease p 199 Install the spacer Clean and greas...

Page 111: ...right chain adjusters must be in the same position relative to the reference marks Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Thread greased Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a pressure point Take the motorcycle off of the rear wheel stand p 80 Check the chain tension p 87 12 5 Checking rear hub shock absorbers x Info The engin...

Page 112: ...er of accidents Uncontrollable vehicle handling in the event of a flat tire In the interest of safety replace damaged or worn tires immediately Your authorized KTM workshop will be glad to help Warning Danger of 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...

Page 113: ... condition and air pressure of the tires all have a major impact on the handling of the motorcycle Worn tires have a negative effect on vehicle handling especially on wet surfaces 400602 10 Check the front and rear tires for cuts run in objects and other damage If the tires exhibit cuts run in objects or other damage Change the tires Check the depth of the tread Info Note local national regulation...

Page 114: ...r If a tire is more than five years old Change the tires 12 7 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life 400695 01 Remove the dust cap Check the tire air pressure when the tires are cold Tire air pressure solo Front 2 2 bar 32 psi Rear 2 2 bar 32 ...

Page 115: ...WHEELS TIRES 113 Mount the dust cap Info The rubber seal in the dust cap prevents air from leaking out of the tire if the valve is faulty ...

Page 116: ...well ventilated areas In the event of skin contact rinse with large amounts 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 wi...

Page 117: ...tach rubber band Pull the battery up and out of the battery rack 13 2 Installing the battery x 101142 11 Position the battery in the battery rack Info The terminals of the battery must face in the direction of travel Attach rubber band Reconnect the positive plus cable of the battery Position positive terminal cover ...

Page 118: ...and battery gases Keep the battery away from sparks or open flames Charge only in well ventilated areas In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Warning Environmental hazard Battery parts and acid are harmful to the environment Do not discard batteries with the household trash Di...

Page 119: ... 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 an extended period it will become over discharged and sulfate destroying the battery The ...

Page 120: ...er remove lid Charge the battery at no more than 10 of the capacity specified on battery housing Switch off the charger after charging Disconnect the battery Guideline The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the motorcycle is not in use 3 months Mount the seat p 82 13 4 Changing the main fuse Warning Fire hazard The electrical system...

Page 121: ...e the seat p 81 101143 10 Remove protection covers Remove the faulty main fuse Info A defective fuse can be identified by the burned out fuse wire A reserve fuse is located in the starter relay Install a new main fuse Fuse 58011109130 p 186 Tip Place the spare fuse in the starter relay so that it is available if needed Attach the protection covers Mount the seat p 82 ...

Page 122: ...ibed amperage Never by pass or repair fuses Info The fuse box containing the fuses of individual power consumers is located under the seat Switch off all power consumers and the engine Remove the seat p 81 101144 10 Open fuse box cover Check the fuses Info A defective fuse can be identified by the burned out fuse wire Spare fuses are also found in the storage compartment Remove the faulty fuse ...

Page 123: ...diator fan Fuse POWER RELAY 10 A ignition EFI control unit Fuse ACC1 CLOCK 10 A combination instrument socket supplementary devices permanent positive alarm system optional Fuse ACC2 10 A supplementary equipment accessories connected to the ignition switch Fuse ABS OPTIONAL not used Use spare fuses with the correct rating only Fuse 58011109110 p 186 Fuse 58011109115 p 186 Tip Insert the spare fuse...

Page 124: ...e lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Switch off all power consumers and the engine 101145 10 Remove screws 101146 10 Cover the fender with a cloth Swing the headlight mask forward and pull it upward out of holding lugs ...

Page 125: ... on both sides squeeze and fold down Remove headlight bulb Position the new headlight bulb in the headlight housing Low beam high beam H4 socket P43t p 186 Info Insert the headlight bulb so that the bayonet lugs latch into the slots Position the retaining clamp 700592 10 Mount rubber cap Plug in connector ...

Page 126: ...chassis screws M6 10 Nm 7 4 lbf ft Check that the lighting is functioning properly 13 7 Changing the parking light bulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Switch off all power consumers and the engine ...

Page 127: ...ELECTRICAL SYSTEM 125 101145 10 Remove screws 101146 10 Cover the fender with a cloth Swing the headlight mask forward and pull it upward out of holding lugs ...

Page 128: ...light carefully out of the holder Remove the bulb Position a new light bulb in the holder Parking light W5W socket W2 1x9 5d p 186 Carefully position the holder with the bulb into the holder in the headlight 101146 12 Position holes onto holding lugs ...

Page 129: ...e lamp and keep it free of grease before mounting 101147 10 Remove the screw on the rear of the turn signal housing Carefully remove diffuser Press bulb carefully into the socket turn it counterclockwise by about 30 and pull it out of the socket Press the new bulb carefully into the socket and turn it clockwise until it stops Turn signal RY10W socket BAU15s p 186 Check the turn signal to make sure...

Page 130: ...lb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Remove the seat p 81 101148 10 Remove screws Remove the grab handles ...

Page 131: ...ELECTRICAL SYSTEM 129 101149 10 Remove screws Remove screws on the left and right rear side part Remove the rear side part 101150 10 Remove screws Remove the top part ...

Page 132: ...t out of the socket Press the new bulb carefully into the socket and turn it clockwise until it stops Brake light P21W socket BA15s p 187 Insert the bulb socket into the tail light and turn clockwise until it stops Check that the brake light system is functioning properly 101150 10 Position the rear top part Mount and tighten screws Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft ...

Page 133: ...7 lbf ft Mount and tighten screws on the left and right rear side part Guideline Screw rear side part EJOT Initial screw con nection 3 3 Nm 2 43 lbf ft Subsequent screw connection 2 Nm 1 5 lbf ft 101148 10 Position the grab handles Mount and tighten screws Guideline Remaining chassis screws M8 25 Nm 18 4 lbf ft Mount the seat p 82 ...

Page 134: ...bs Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Remove the seat p 81 101148 10 Remove screws Remove the grab handles ...

Page 135: ...ELECTRICAL SYSTEM 133 101149 10 Remove screws Remove screws on the left and right rear side part Remove the rear side part 101150 10 Remove screws Remove the top part ...

Page 136: ...ght bulb in the holder Tail light W5W socket W2 1x9 5d p 187 Carefully position the holders with the bulbs into the holder in the tail light Check that the tail light bulbs are functioning properly 101150 10 Position the rear top part Mount and tighten screws Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft ...

Page 137: ...7 lbf ft Mount and tighten screws on the left and right rear side part Guideline Screw rear side part EJOT Initial screw con nection 3 3 Nm 2 43 lbf ft Subsequent screw connection 2 Nm 1 5 lbf ft 101148 10 Position the grab handles Mount and tighten screws Guideline Remaining chassis screws M8 25 Nm 18 4 lbf ft Mount the seat p 82 ...

Page 138: ... 01 Remove screws Remove the license plate lamp cover 700603 01 Pull holder carefully out of the bracket Remove the bulb Position a new light bulb in the holder License plate lamp W5W socket W2 1x9 5d p 187 Carefully position the holder with the bulb into the bracket ...

Page 139: ... of the headlight Make another mark at a distance of under the first mark Guideline Distance 5 cm 2 in Park the vehicle at a distance of vertically in front of the wall and switch on the low beam headlight Guideline Distance 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 w...

Page 140: ...nterclockwise to reduce the headlight range 13 14 Activating deactivating the ignition key Info The orange programming key must only be used for activating and deactivating If a black ignition key is lost or replaced the black ignition keys must be activated deactivated using the orange programming key This will also prevent the vehicle from being operated without authorization with the lost black...

Page 141: ...p lights up Switch off the ignition by turning the orange programming key to the OFF position Pull out the programming key Insert the black ignition key in the ignition lock Switch on the ignition by turning the ignition key to the ON position FI Warning lamp MIL lights up switches off and then starts to flash Immobilizer indicator lamp lights up switches off briefly and lights up again Switch off...

Page 142: ...y Press the emergency OFF switch into the position 101154 10 Insert the orange programming key in the ignition lock Switch on the ignition by turning the orange programming key to the ON position FI Warning lamp MIL lights up switches off and then starts to flash Immobilizer indicator lamp lights up Switch off the ignition by turning the orange programming key to the OFF position Switch on the ign...

Page 143: ...ts up Switch off the ignition by turning the orange programming key to the OFF position Pull out the programming key Insert the black ignition key in the ignition lock Switch on the ignition by turning the ignition key to the ON position FI Warning lamp MIL lights up switches off and then starts to flash Immobilizer indicator lamp lights up switches off briefly and lights up again Switch off the i...

Page 144: ...umber of flashes equals the number of functional black ignition keys includ ing the orange programming key Switch off the ignition by turning the orange programming key to the OFF position Pull out the programming key All black ignition keys are activated included in this job sequence are activated ...

Page 145: ...er the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect The heat expansion causes the surplus coolant to flow into the compensating tank When the temperature falls this surplus coolant is sucked back into the cooling system 14 2 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under ...

Page 146: ...Condition The engine is cold Stand the motorcycle upright on a horizontal surface Reset the fuel tank p 83 101156 10 Remove radiator cap and plug from the compensating tank Check the coolant antifreeze 25 45 C 13 49 F If the coolant antifreeze does not meet specifications Correct the coolant antifreeze Check the coolant level in the compensating tank The coolant level must be between the upper mar...

Page 147: ...on for the coolant loss Alternative 1 Coolant p 194 Alternative 2 Coolant mixed ready to use p 194 If more coolant needed to be added than the specified value 0 50 l 0 53 qt Fill bleed the cooling system x p 148 Mount radiator cap 14 3 Checking the coolant level in the compensating tank Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not re...

Page 148: ...ndition The engine is cold The radiator is completely full Stand the motorcycle on a horizontal surface 101158 10 Check the coolant level in the compensating tank The coolant level must be between the upper marking and lower marking If the coolant level in the compensating tank does not meet specifications but the tank is not empty Remove the compensating tank cap Add coolant to the upper marking ...

Page 149: ...Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolant out of the reach of children Reset the fuel ta...

Page 150: ...nous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolant out of the reach of children Reset the fuel tank p 83 101161 1...

Page 151: ...e vent hole and then immediately mount and tighten the bleeder screw Alternative 1 Coolant p 194 Alternative 2 Coolant mixed ready to use p 194 Fill the radiator completely with coolant Mount the radiator cap Lean the vehicle on the side stand Check the coolant level in the compensating tank p 145 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousnes...

Page 152: ...rature display light up Stop the engine and allow it to cool down When the engine is cool check the coolant level in the radiator and add coolant if nec essary Check the coolant level in the compensating tank p 145 Position the fuel tank p 84 ...

Page 153: ...play in the throttle cable x p 152 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and let it run idle Move the handlebar to and fro over t...

Page 154: ...rve plug in connector 101170 01 The plug in connection is located under the seat in front of the fuse box By disconnecting the plug in connector the ignition curve for fuel with an octane rating below 95 ROZ 95 RON 95 PON 91 is activated While the engine will have a slightly lower power output this setting prevents engine damage by hindering spark knocking due to poor fuel quality Possible states ...

Page 155: ...disconnected Fuel with an octane rating of 80 to 94 RON can be used for one tank full p 152 Activate the ignition curve for fuel with an octane rating of 95 or higher ROZ 95 RON 95 PON 91 Connect plug in connector Plug in connector connected Fuel with an octane rating of 95 or higher can be used p 152 Mount the seat p 82 15 5 Checking the basic position of the shift lever 0 0 0 A A 400692 10 Sit o...

Page 156: ...of the shift lever and shift shaft Mount the shift lever 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 screw Guideline Screw shift lever M6 10 Nm 7 4 lbf ft Loctite 243 ...

Page 157: ... exhaust extraction system Start the engine and run it until it reaches operating temperature Six bars of the temperature display light up 101168 10 Switch off the engine Park the motorcycle on a horizontal surface in a vertical position not on the side stand Info After switching off the engine wait one minute before checking the level Check the engine oil level at oil level viewer The engine oil ...

Page 158: ...l screens x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns 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 regulati...

Page 159: ...0 Place a suitable container under the engine Remove the oil drain plug with the magnet and seal ring Fully drain the engine oil out of the engine 700610 10 Remove screws and cover 700612 10 Pull oil screen out of the engine case with pliers ...

Page 160: ...line to one side 700615 10 Pull oil sieve out of the oil tank 700617 10 Remove screw connections and move the oil line to one side Remove screws Take off oil filter cover with the O ring Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Clean all oil screens and oil drain plugs with a magnet Clean all sealing surfaces ...

Page 161: ...all oil filter cover Mount and tighten the screws Guideline Remaining engine screws M5 6 Nm 4 4 lbf ft Position the oil line Mount and tighten screw cap Guideline Nut oil line M16x1 5 25 Nm 18 4 lbf ft 700614 10 Check seal ring of the oil sieve for damage and correct seating Insert oil sieve into the oil tank ...

Page 162: ...n plug with magnet M12x1 5 25 Nm 18 4 lbf ft 700611 10 Mount oil drain plug with the magnet and new seal ring and tighten Guideline Oil drain plug with magnet M22x1 5 35 Nm 25 8 lbf ft 700616 10 Slide oil sieve into the engine case with the TOP marking facing up Check the form ring in cover for damage and correct seating Position the cover Mount and tighten the screws Guideline Screw clutch cover ...

Page 163: ... the top marking Mount the plug Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and run it until it reaches operating temperature Six bars ...

Page 164: ...e The engine oil level must be corrected when the engine is warm 101169 10 Remove plug and add engine oil to the top marking Condition External temperature 0 C 32 F Engine oil SAE 10W 50 p 195 Condition External temperature 0 C 32 F Engine oil SAE 5W 40 p 195 Info For optimal performance of the engine oil do not mix different types of engine oil We recommend changing the engine oil if necessary Mo...

Page 165: ...uid 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 Remove coarse dirt particles with a gentle spray of water Spray very dirty areas with a normal motorc...

Page 166: ...applying the brakes occasionally Info The heat produced causes water at inaccessible positions in the engine and on the brakes to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 86 Treat bare metal parts except for brake discs and exhaust system with anti corrosion materials Cleaning and preserving materials for metal rubber and plastic p 198...

Page 167: ...d water Warm water would enhance the corrosive effects of salt 401060 01 Clean the motorcycle p 163 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with a wax based anti corrosion substance Info To prevent serious reduction of the braking efficiency make sure no anti corrosion substance gets on to the brake discs After riding on salted roads thoroughly wash ...

Page 168: ...sible so that you can fill up with fresh fuel when you put the motorcycle back into operation Clean the motorcycle p 163 Change the engine oil and filter clean the oil screens x p 156 Check the antifreeze and coolant level p 143 Check the tire air pressure p 112 Remove the battery x p 114 Recharge the battery x p 116 Guideline Storage temperature of battery without direct sunshine 0 35 C 32 95 F S...

Page 169: ...annot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 18 2 Preparing for use after storage 401059 01 Take the motorcycle off of the front wheel stand p 79 Take the motorcycle off of the rear wheel stand p 80 Recharge the battery x p 116 Install the battery x p 115 Set the clock p 40 Refuel p 65 Perform checks and maintenance measur...

Page 170: ...trol unit x Malfunction in CAN bus communica tion Check the CAN bus communication x Combination instrument defective Check the combination instrument x Control unit for electric start lock defective Check the control unit of the electric start lock x Engine turns only if the clutch lever is drawn The vehicle is in gear Shift the transmission to neutral Defect in safety start system Check the safet...

Page 171: ...on in cooling system Drain the coolant x p 147 Fill bleed the cooling system x p 148 Buckled or damaged radiator hose Change the radiator hose x Fuse FAN blown Change the fuses of individual power consumers p 120 Thermostat defective Check the thermostat x Defect in radiator fan system Check the radiator fan system x Air in cooling system Fill bleed the cooling system x p 148 Warning lamp FI MIL l...

Page 172: ... functional Fuse HORN BRAKE LIGHT SPEEDO blown Change the fuses of individual power consumers p 120 Battery discharged Ignition not switched off when vehicle was parked Recharge the battery x p 116 Battery is not charged by the alternator Check the charging voltage x Combination instrument shows nothing in the display Fuse ACC1 CLOCK blown Change the fuses of individual power consumers p 120 Speed...

Page 173: ...ntrol unit Blink code of immobilizer indica tor lamp 14 Immobilizer indicator lamp flashes 1x short 1 second pause 4x short Error level condition Malfunction in transponder of black ignition key Blink code of immobilizer indica tor lamp 15 Immobilizer indicator lamp flashes 1x short 1 second pause 5x short Error level condition Black ignition key inactive Blink code of immobilizer indica tor lamp ...

Page 174: ... indicator lamp flashes 3x short 1 second pause 1x short Error level condition Malfunction encryption query from EFI control unit to immobilizer control unit Blink code of immobilizer indica tor lamp 32 Immobilizer indicator lamp flashes 3x short 1 second pause 2x short Error level condition Malfunction in CAN bus communication Blink code of immobilizer indica tor lamp 60 Immobilizer indicator lam...

Page 175: ...p FI MIL flashes 7x short Error level condition Throttle position sensor circuit B input signal too low Throttle position sensor circuit B input signal too high Blink code FI of warning lamp MIL 09 Warning lamp FI MIL flashes 9x short Error level condition Manifold absolute pressure sensor cylinder 1 input signal too low Manifold absolute pressure sensor cylinder 1 input signal too high Blink code...

Page 176: ...ir temperature sensor input signal too high Blink code FI of warning lamp MIL 14 Warning lamp FI MIL flashes 1x long 4x short Error level condition Ambient air pressure sensor input signal too low Ambient air pressure sensor input signal too high Blink code FI of warning lamp MIL 15 Warning lamp FI MIL flashes 1x long 5x short Error level condition Rollover sensor A D type input signal too low Rol...

Page 177: ...or level condition Power supply circuit fault Blink code FI of warning lamp MIL 25 Warning lamp FI MIL flashes 2x long 5x short Error level condition Side stand A D type malfunction in circuit Blink code FI of warning lamp MIL 33 Warning lamp FI MIL flashes 3x long 3x short Error level condition Injector cylinder 1 circuit fault Blink code FI of warning lamp MIL 34 Warning lamp FI MIL flashes 3x l...

Page 178: ...or level condition Fuel pump control interruption short circuit to ground Fuel pump control input signal too high Blink code FI of warning lamp MIL 45 FI Warning lamp MIL flashes 4x long 5x short Error level condition Heating lambda sensor cylinder 1 sensor 1 interruption short circuit to ground Heating lambda sensor cylinder 1 sensor 1 input signal too high Blink code FI of warning lamp MIL 46 Wa...

Page 179: ...ning lamp FI MIL flashes 5x long 3x short Error level condition Fuel evaporation system short circuit to ground or open circuit Fuel evaporation system input signal too high Blink code FI of warning lamp MIL 54 Warning lamp FI MIL flashes 5x long 4x short Error level condition Secondary air valve interruption short circuit to ground Secondary air valve input signal too high Blink code FI of warnin...

Page 180: ...old absolute pressure sensor cylinder 2 connection leaks Blink code FI of warning lamp MIL 81 Warning lamp FI MIL flashes 8x long 1x short Error level condition Immobilizer control unit circuit fault Blink code FI of warning lamp MIL 91 Warning lamp FI MIL flashes 9x long 1x short Error level condition Malfunction in CAN bus communication ...

Page 181: ...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 L ring 1 tapered compression piston ring 1 oil scraper ring Engine lubrication Dry sump lubrication system with two rotor pumps Primary transmission 35 67 Clutch Multidisc clutch in oil bath hydraulicall...

Page 182: ...AR8BI9 Spark plug electrode gap 0 8 mm 0 031 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 400 1 500 rpm Cold start device Electric starter 22 1 Capacity engine oil Engine oil 3 80 l 1 004 US gal External temperature 0 C 32 F Engine oil SAE 10W 50 p 195 External temperature 0 C 32 F Engine oil SAE 5W 40 p 195 22 2 Capacity coolant Coolant 2 30 l 2 43 qt Coola...

Page 183: ...6 10 Nm 7 4 lbf ft Screw in alternator cover M6 10 Nm 7 4 lbf ft Screw bearing bolt in alternator cover M6 10 Nm 7 4 lbf ft Loctite 243 Screw camshaft bearing support M6 10 Nm 7 4 lbf ft Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch spring M6 10 Nm 7 4 lbf ft Screw engine case M6 10 Nm 7 4 lbf ft Screw freewheel holder M6 10 Nm 7 4 lbf ft Loctite 243 Screw freewheel ring M6 13 Nm 9 6 lbf ft ...

Page 184: ...ng chain guide rail M8 15 Nm 11 1 lbf ft Loctite 243 Bearing bolt timing chain tensioning rail M8 20 Nm 14 8 lbf ft Loctite 243 Screw camshaft bearing support M8 Step 1 10 Nm 7 4 lbf ft Step 2 18 Nm 13 3 lbf ft Screw clutch cover M8 15 Nm 11 1 lbf ft Screw cylinder head M8 Step 1 18 Nm 13 3 lbf ft Step 2 23 Nm 17 lbf ft Loctite 243 Stud exhaust flange M8 15 Nm 11 1 lbf ft Bearing bolt timing gears...

Page 185: ...5 12 Nm 8 9 lbf ft Plus cylinder head 2nd cylinder M12x1 5 25 Nm 18 4 lbf ft Plug oil filter housing M14x1 5 15 Nm 11 1 lbf ft Loctite 243 Bleeder flange alternator cover M16x1 5 10 Nm 7 4 lbf ft Loctite 243 Plug timing chain tensioner M16x1 5 20 Nm 14 8 lbf ft Rotor screw M16x1 5 150 Nm 110 6 lbf ft Loctite 243 Nut balancer shaft M20x1 5 120 Nm 88 5 lbf ft Loctite 243 Nut engine sprocket M20x1 5 ...

Page 186: ...TECHNICAL DATA ENGINE TIGHTENING TORQUES 184 Nut primary gear M33LHx1 5 130 Nm 95 9 lbf ft Loctite 243 ...

Page 187: ...ble disc brake with radially screwed four piston brake calipers float mounted brake discs Rear Single disc brake with dual piston brake caliper rigid mounted brake disc Brake discs diameter Front 305 mm 12 01 in Rear 240 mm 9 45 in Brake discs wear limit Front 4 5 mm 0 177 in Brake disc wear limit Rear 4 5 mm 0 177 in Tire air pressure solo Front 2 2 bar 32 psi Rear 2 2 bar 32 psi Tire air pressur...

Page 188: ...sible front axle load 160 kg 353 lb Maximum permissible rear axle load 250 kg 551 lb Maximum permissible total weight 400 kg 882 lb Battery YTZ14S Battery voltage 12 V Nominal capacity 11 2 Ah maintenance free Fuse 58011109110 10 A Fuse 58011109115 15 A Fuse 58011109130 30 A 24 1 Lighting equipment Low beam high beam H4 socket P43t 12 V 60 55 W Parking light W5W socket W2 1x9 5d 12 V 5 W Instrumen...

Page 189: ...4 2 Tires Front tire Rear tire 120 70 ZR 17 M C 58W TL Pirelli DRAGON SUPERCORSA PRO 180 55 ZR 17 M C 73W TL Pirelli DRAGON SUPERCORSA PRO Additional information is available in the Service section under http www ktm com 24 3 Capacity fuel Total fuel tank capacity approx 15 l 4 US gal Super unleaded ROZ 95 RON 95 PON 91 p 197 Fuel reserve approx 3 5 l 3 7 qt ...

Page 190: ...ng Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload Preload Adjuster Comfort 5 turns Standard 5 turns Sport 3 turns Full payload 3 turns Spring length with preload spacer s 386 mm 15 2 in Spring rate Medium standard 7 5 N mm 42 8 lb in Fork length 877 mm 34 53 in Air chamber length 100 20 mm 3 94 0 79 in Fork oil per fork leg 750 ml 25 36 fl oz Fork oil SA...

Page 191: ...s Full payload 15 clicks Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload Comfort 11 mm 0 43 in Standard 11 mm 0 43 in Sport 11 mm 0 43 in Full payload 13 mm 0 51 in Spring rate Medium standard 140 N mm 799 lb in Spring length 200 mm 7 87 in ...

Page 192: ...TECHNICAL DATA SHOCK ABSORBER 190 Gas pressure 10 bar 145 psi Static sag 20 mm 0 79 in Fitted length 372 mm 14 65 in Shock absorber fluid Shock absorber oil SAE 2 5 50180342S1 p 196 ...

Page 193: ...ctite 243 Nut tail light M6 8 Nm 5 9 lbf ft Remaining chassis nuts M6 15 Nm 11 1 lbf ft Remaining chassis screws M6 10 Nm 7 4 lbf ft Screw chain sliding guard M6 6 Nm 4 4 lbf ft Loctite 243 Screw foot brake cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw fuel pump M6 6 Nm 4 4 lbf ft Screw fuel tap M6 6 Nm 4 4 lbf ft Screw magnetic holder on side stand M6 6 Nm 4 4 lbf ft Loctite 243 Screw seat brack...

Page 194: ...18 4 lbf ft Loctite 243 Screw steering stem M8 20 Nm 14 8 lbf ft Screw top triple clamp M8 20 Nm 14 8 lbf ft Engine carrying screw M10 45 Nm 33 2 lbf ft Remaining chassis nuts M10 50 Nm 36 9 lbf ft Remaining frame bolts M10 45 Nm 33 2 lbf ft Screw handlebar support M10 20 Nm 14 8 lbf ft Screw side stand M10 35 Nm 25 8 lbf ft Loctite 243 Screw side stand bracket M10 45 Nm 33 2 lbf ft Loctite 243 Sc...

Page 195: ... 5 80 Nm 59 lbf ft Thread greased Screw top shock absorber M14x1 5 80 Nm 59 lbf ft Thread greased Nut oil line M16x1 5 25 Nm 18 4 lbf ft Nut swingarm pivot M19x1 5 130 Nm 95 9 lbf ft Thread greased Screw steering head M20x1 5 12 Nm 8 9 lbf ft Bolt front axle M25x1 5 45 Nm 33 2 lbf ft Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Thread greased ...

Page 196: ...x 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 us...

Page 197: ...rresponding 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 200 SAE p 200 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 Supplie...

Page 198: ...lic fluid 15 According to ISO VG 15 Guideline Use only hydraulic oil 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 200 SAE 2 5 Guideline Use only oils that comply with the specified standards se...

Page 199: ...SUBSTANCES 197 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91 ...

Page 200: ...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 High luster polish for paint Guideline KTM recommends Motorex products Supplier Motorex Moto Polish ...

Page 201: ...M recommends Motorex products Supplier Motorex Bike Grease 2000 Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Synthetic ...

Page 202: ...ce intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines With 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 203: ...ear brake checking 100 Brake light bulb changing 128 Brake linings 97 front brake checking 97 rear brake checking 102 Brakes 62 Braking 62 C Chain checking 90 cleaning 86 dirt checking 86 Chain tension adjusting 88 checking 87 Chassis number 26 Clutch checking correcting fluid level 93 Clutch lever 30 basic position adjusting 92 Combination instrument 35 clock setting 40 coolant temperature indica...

Page 204: ... Electric starter button 35 Emergency OFF switch 34 Engine running in 53 Engine number 28 Engine oil adding 162 changing 156 draining 156 refilling 161 Engine oil level checking 155 Engine sprocket checking 90 Environment 10 F Filler cap closing 46 opening 45 Foot brake lever 50 free travel checking 98 Fork 70 compression damping adjusting 70 fork legs bleeding 81 rebound adjusting 71 spring prelo...

Page 205: ...l quality 153 plug in connector 152 Ignition key activating deactivating 138 Ignition lock 33 Immobilizer 34 Indicator lamps 37 K Key number 27 L License plate lamp changing 136 Light switch 31 Loading the vehicle 53 M Main fuse changing 118 Motorcycle cleaning 163 raising with the front wheel stand 79 raising with the rear wheel stand 80 taking off of the front wheel stand 79 taking off of the re...

Page 206: ...Rear wheel installing 108 removing 107 Refueling fuel 65 Riding 59 starting off 58 S Seat mounting 82 removing 81 Seat lock 47 Service 8 Service schedule 67 69 Shift lever 49 basic position adjusting 154 basic position checking 153 Shifting 59 Shock absorber 70 compression damping general 74 compression damping high speed adjusting 75 compression damping low speed adjusting 74 rebound damping adju...

Page 207: ... 184 fork 188 shock absorber 189 190 Throttle grip 31 Tire air pressure checking 112 Tire condition checking 110 Tool set 48 Transport 9 Troubleshooting 168 170 Turn signal bulb changing 127 Turn signal switch 32 Type label 26 U Use definition 8 V View of vehicle front left 22 rear right side 24 W Warning of slippery roads 44 Warranty 8 Work rules 9 ...

Page 208: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 11 2010 Photo Mitterbauer 3211661en 3211661en ...