KTM 690 SMC EU, 690 SMC AUS/UK (Art. no. 3211659en). Manual (2011)

DEAR KTM CUSTOMER

Congratulations on your decision to buy a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you

enormous pleasure if you service and maintain it accordingly.

We wish you a lot of enjoyment in riding this vehicle!

Enter the serial numbers of your vehicle below.

Chassis number ( p. 16)

Dealer's stamp

Engine number ( p. 17)

Key number ( p. 17)

The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing devel-

opment and design of our vehicles cannot, however, be completely excluded.

All specifications are non-binding. KTM Sportmotorcycle AG in particular 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 options, devi-

ations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment

that does not belong to the regular scope of delivery.

DEAR KTM CUSTOMER

Reproduction, even in part, as well as copying of all kinds, 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

TABLE OF CONTENTS

MEANS OF REPRESENTATION

Combination instrument - time

IMPORTANT INFORMATION

Setting the clock

VIEW OF VEHICLE

Combination instrument - display ODO

View of vehicle, front left

Combination instrument - setting/resetting TRIP 1

View of vehicle, rear right

Combination instrument - setting/resetting TRIP 2

SERIAL NUMBERS

Combination instrument - TRIP F display

Chassis number

Combination instrument - coolant temperature indicator

Type label

Opening the filler cap

Engine number

Closing filler cap

Key number

Seat release

Fork part number

Handrails

Shock absorber part number

Passenger footrests

CONTROLS

Shift lever

Clutch lever

Foot brake lever

Hand brake lever

Side stand

Throttle grip

PREPARING FOR USE

Light switch

Advice on first use

Turn signal switch

Running in the engine

Horn button

Loading the vehicle

Emergency OFF switch

RIDING INSTRUCTIONS

Electric starter button

Performing checks and vehicle care when preparing for

use

Ignition/steering lock

Combination instrument

Starting

Starting off

Combination instrument - function buttons

Shifting, riding

Combination instrument - tachometer

Combination instrument - indicator lamps

Braking

Stopping, parking

Combination instrument - display

Refueling

Combination instrument - speedometer

Setting kilometers or miles

TABLE OF CONTENTS

SERVICE PLAN

Checking/rectifying the fluid level of the hydraulic clutch

Service schedule

BRAKES

TUNING THE CHASSIS

Adjusting the basic position of the hand brake lever

Fork/shock absorber

Checking the brake discs

Adjusting the compression damping of the fork

Checking the front brake fluid level

Adjusting the rebound damping of the fork

Adding front brake fluid x

Compression damping of the shock absorber

Checking the front brake linings

Adjusting the low-speed compression damping of the shock

Checking the free travel of foot brake lever

absorber

Adjusting the basic position of the foot brake lever x

Adjusting the high-speed compression damping of the

Checking rear brake fluid level

shock absorber

Adding rear brake fluid x

Adjusting the rebound damping of the shock absorber

Checking the rear brake linings

SERVICE WORK ON THE CHASSIS

WHEELS, TIRES

Raising the motorcycle with the front wheel stand

Removing front wheel x

Taking the motorcycle off of the front wheel stand

Installing the front wheel x

Raising the motorcycle with the rear wheel stand

Removing rear wheel x

Taking the motorcycle off of the rear wheel stand

Installing the rear wheel x

Bleeding the fork legs

Checking the rear hub rubber dampers x

Removing the seat

Checking the tire condition

Mounting the seat

Checking the tire air pressure

Removing the air filter x

Checking the spoke tension

Installing the air filter x

ELECTRICAL SYSTEM

Checking the chain for dirt

Removing the battery x

Cleaning the chain

Installing the battery x

Checking the chain tension

Recharging the battery x

Adjusting the chain tension

Check the chain, rear sprocket, engine sprocket and chain

Changing the main fuse

101

guide

Changing fuses of individual power consumers

103

Adjusting basic position of clutch lever

Removing the headlight mask with the headlight

105

TABLE OF CONTENTS

Installing the headlight mask with the headlight

106

STORAGE

134

Changing the headlight bulb

107

Storage

134

Changing the parking light bulb

108

Preparing for use after storage

135

Changing the turn signal bulb

109

TROUBLESHOOTING

136

Checking the low beam headlight adjustment

110

BLINK CODE

139

Adjusting the headlight range

111

TECHNICAL DATA - ENGINE

144

COOLING SYSTEM

112

Capacity - engine oil

145

Cooling system

112

Capacity - coolant

145

Checking the antifreeze and coolant level

112

TECHNICAL DATA - ENGINE TIGHTENING TORQUES

146

Checking the coolant level

114

TECHNICAL DATA - CHASSIS

149

Draining the coolant x

116

Lighting equipment

150

Filling the cooling system x

117

Tires

151

TUNING THE ENGINE

119

Capacity - fuel

151

Checking the play in the throttle cable

119

TECHNICAL DATA - FORK

152

Adjusting the play in the throttle cable x

120

TECHNICAL DATA - SHOCK ABSORBER

153

Adjusting the engine characteristic

120

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES

155

SERVICE WORK ON THE ENGINE

122

SUBSTANCES

158

Checking the engine oil level

122

AUXILIARY SUBSTANCES

162

Changing the engine oil and filter, cleaning the oil

STANDARDS

164

screens x

123

INDEX

165

Draining the engine oil x

123

Removing the oil filter x

124

Cleaning the oil screens x

126

Installing the oil filter x

128

Filling up with engine oil x

128

Adding engine oil

129

CLEANING, CARE

131

Cleaning the motorcycle

131

Protective treatment for winter operation

133

MEANS OF REPRESENTATION

Symbols used

The meaning of specific symbols is described below.

Indicates an expected reaction (e.g. of a work step or a function).

Indicates an unexpected reaction (e.g. of a work step or a function).

All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your

own safety, have these jobs performed in an authorized KTM workshop! There, your motorcycle will be serviced opti-

mally by specially trained experts using the specialist tools required.

Indicates a page reference (more information is provided on the specified page).

Formats used

The following typographical formats are used.

Specific name

Identifies a proprietary name.

Name^®

Identifies a protected name.

Brand™

Identifies a brand in merchandise traffic.

IMPORTANT INFORMATION

Use definition

KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race

courses or offroad.

Info

The motorcycle is authorized for public road traffic in the homologous version only.

Service

A prerequisite for fault-free operation and avoiding premature wear is compliance with the instructions for maintenance, care and tuning of

the engine and suspension provided in the owner's manual. Poor adjustment and tuning of the engine and chassis can lead to damage and

breakage of components.

Using the motorcycle in extreme conditions such as very muddy or 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.

It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a much

longer service life for your motorcycle.

Warranty

The work prescribed in the service plan must only be carried out in an authorized KTM workshop and confirmed in the service record; oth-

erwise all warranty claims will be disregarded. No warranty claim can be met for damage resulting from manipulation and/or other changes

to the vehicle.

Fuel, oils, etc.

You should use the fuels, oils and greases according to specifications as listed in the owner's manual.

IMPORTANT INFORMATION

Spare parts, accessories

For your own safety, only use spare parts and accessory products that have been 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.

Some spare parts and accessory products are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise you.

You will find the current KTM PowerParts for your vehicle on the KTM website.

International KTM Website: http://www.ktm.com

Work rules

Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parenthe-

ses. Example: 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.

If a thread lock (e.g. Loctite^®) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its usage.

Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or

worn parts.

Ensure that the vehicle is roadworthy after completing repair and maintenance work.

Transport

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 substances. Do not place objects on the vehicle while it is still warm from being

run. Always let the vehicle cool first.

IMPORTANT INFORMATION

- Switch off the engine and remove the ignition key.

- Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

Environment

Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential

problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that

such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle

legally, display environmental consciousness, and respect the rights of others.

Notes/warnings

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.

IMPORTANT INFORMATION

Grades of risks

Danger

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not

taken.

Warning

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Caution

Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

Note

Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Warning

Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.

Owner's manual

- It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful information

and tips to help you operate and handle your motorcycle. Only then will you find out how to customize the motorcycle ideally for your

own use and how you can protect yourself from injury. The owner's manual also contains important information on servicing the motor-

cycle.

- The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.

VIEW OF VEHICLE

Ignition/steering lock ( p. 23)

Light switch ( p. 20)

Turn signal switch ( p. 21)

Horn button ( p. 21)

Rear mirror

Combination instrument ( p. 23)

Emergency OFF switch ( p. 22)

Electric starter button ( p. 22)

Throttle grip ( p. 20)

Chassis number ( p. 16)

Passenger footrests ( p. 34)

Shock absorber, rebound adjustment

Foot brake lever ( p. 36)

Level viewer, engine oil

CONTROLS

Throttle grip

5.3

The throttle grip  is fitted on the right side of the handlebar.

101069-10

Light switch

5.4

The light switch  is fitted on the left side of the handlebar.

Possible states

Low beam on - Light switch is turned downwards. In this position, the low

beam and tail light are switched on.

High beam on - Light switch is turned upwards. In this position, the high

beam and the tail light are switched on.

100222-10

CONTROLS

Turn signal switch

5.5

The turn signal switch  is fitted on the left side of the handlebar.

Possible states

Turn signal off

Turn signal light, left, on - Turn signal switch pressed to the left. The turn

signal switch returns automatically to the central position after use.

Turn signal light, right, on - Turn signal switch pressed to the right. The

turn signal switch returns automatically to the central position after use.

100223-10

To switch off the turn signal light, press the turn signal switch towards the switch case.

Horn button

5.6

The horn button  is fitted on the left side of the handlebar.

Possible states

• Horn button in neutral position

• Horn button pressed - The horn is operated in this position.

100224-10

CONTROLS

Emergency OFF switch

5.7

The emergency OFF switch  is fitted on the right side of the handlebar.

Possible states

Emergency OFF switch off - In this position, the ignition circuit is inter-

rupted, a running engine stops, and the engine cannot be started.

Emergency OFF switch on - This position is necessary for operation as the

ignition circuit is closed.

100225-10

Electric starter button

5.8

The electric starter button  is fitted on the right side of the handlebar.

Possible states

• Electric starter button in basic position

• Electric starter button pressed - In this position, the electric starter is actuated.

100226-10

CONTROLS

Ignition/steering lock

5.9

The ignition/steering lock  is located in front of the seat.

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.

Steering locked - In this position, the ignition circuit is interrupted and the

600825-01

steering locked. The ignition key can be removed.

Combination instrument

5.10

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

400832-10

CONTROLS

Combination instrument - function buttons

5.11

You can change the display mode with the MODE button .

Possible display modes are distance traveled (ODO), trip master 1 (TRIP 1) and trip mas-

ter 2 (TRIP 2).

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.

400833-10

Combination instrument - tachometer

5.12

The tachometer  shows the engine speed in revolutions per minute.

The red marking  shows the excess speed range of the engine.

400834-10

CONTROLS

Combination instrument - indicator lamps

5.13

The indicator lamps offer additional information about the operating state of the motorcy-

cle.

Possible states

The turn signal indicator lamp flashes green simultaneously with the turn

signal - The turn signal is switched on.

The idle speed indicator lamp lights up green - The transmission is shifted

to idle.

The high beam indicator lamp lights up blue - The high beam is switched

400835-01

on.

Temperature warning lamp lights up red - Coolant temperature has reached

a critical value.

Fuel level warning lamp lights up orange - Fuel level has reached the

reserve mark. Display switched to TRIP F.

FI warning lamp (MIL) lights up/flashes orange - The OBD (onboard diagno-

sis) has identified an emissions- or safety-critical fault.

Battery warning lamp lights up red - Voltage in vehicle system too low.

CONTROLS

Combination instrument - display

5.14

When you switch on the ignition, all display segments light up for a second as a function

test.

400836-01

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.

400881-01

CONTROLS

- Switch on the ignition by turning the ignition key to position ON

– Press the MODE button repeatedly until the ODO mode is active.

- Keep the MODE button pressed until the display mode changes from km/h to mph or

from mph to km/h.

400839-01

5.17

Combination instrument - time

The time is shown in area  of the display.

Info

After reconnecting the battery or changing the fuse, the time must be reset.

400838-11

5.18

Setting the clock

Condition

The motorcycle is stationary.

CONTROLS

- Switch on the ignition by turning the ignition key to position ON

– Press the MODE button repeatedly until the ODO mode is active.

- Keep the MODE button and the SET button pressed simultaneously.

The time display begins to flash.

- Press the MODE button to set the hour.

- Press the SET button to set the minute.

- Keep the MODE button and the SET button pressed simultaneously.

The time is set.

400838-01

Combination instrument - display ODO

5.19

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.

400839-01

Combination instrument - setting/resetting TRIP 1

5.20

Info

The TRIP 1 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.

CONTROLS

- Switch on the ignition by turning the ignition key to position ON

– Press the MODE button repeatedly until the TRIP 1 mode is active.

- Keep the SET button pressed.

The TRIP 1 display is set to 0.0.

400840-01

Combination instrument - setting/resetting TRIP 2

5.21

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.

- Switch on the ignition by turning the ignition key to position ON

– Press the MODE button repeatedly until the TRIP 2 mode is active.

- Keep the SET button pressed.

The TRIP 2 display is set to 0.0.

400841-01

CONTROLS

Combination instrument - TRIP F display

5.22

If the fuel level drops to the reserve 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.

400842-01

Combination instrument - coolant temperature indicator

5.23

The temperature display consists of 12 bars. The more bars that light up, the hotter the

coolant. When the upper bar lights up, all bars in the display begin to flash and the temper-

ature warning lamp lights up.

Possible states

• Engine cold - Up to four bars light up.

• Engine warm - Five to eleven bars light up.

• Engine hot - All twelve bars flash.

700124-01

CONTROLS

Opening the filler cap

5.24

Danger

Fire hazard Fuel is highly flammable.

- Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is

spilt, especially on hot vehicle components. Clean up spilt fuel 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 vapors. If fuel gets into your eyes, rinse immediately

with water and contact a 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. Store fuel in a suitable canister according to regulations

and keep it out of the reach of children.

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.

- Lift the cover of filler cap  and insert the ignition key.

- Turn the ignition key 90° counterclockwise and remove the filler cap.

Info

The filler cap has a tank air vent system.

100227-10

CONTROLS

Handrails

5.27

The handrails  are used for moving the motorcycle around.

When you have a passenger, the passenger can hold on the handrails during the journey.

100229-10

Passenger footrests

5.28

The passenger 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.

600640-01

CONTROLS

Foot brake lever

5.30

Foot brake lever  is located in front of the right footrest.

The rear brake is engaged with the foot brake lever.

600485-10

Side stand

5.31

The side stand  is located on the left side of the vehicle.

The side stand is used for parking the motorcycle.

Info

The side stand must be folded up during motorcycle use.

The side stand is coupled with the safety electric starter system - see the riding

instructions.

Possible states

600486-10

• Side stand folded out - The vehicle can be supported on the side stand. The safety

electric starter system is active.

• Side stand folded in - This position is mandatory when riding the motorcycle. The

safety electric starter system is inactive.

PREPARING FOR USE

Advice on first use

6.1

Danger

Danger of accidents Danger arising from the rider's judgement being impaired.

- Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally

impaired.

Warning

Risk of injury Missing or poor protective clothing present an increased safety risk.

- Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear

protective clothing, which must be undamaged and meet legal requirements.

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 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 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 (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved

until the tires have been run in.

PREPARING FOR USE

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.

Info

When using your vehicle, remember that others may feel disturbed by excessive noise.

- Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.

You receive a delivery certificate and the service record at vehicle handover.

- Before your first trip, read the entire operating instructions carefully.

- Get to know the controls.

- Adjust the basic position of clutch lever. ( p. 75)

- Adjust the basic position of hand brake lever. ( p. 77)

- Adjust the basic position of the foot brake lever. x

(

p. 82)

– Get used to handling the vehicle 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 vehicle.

- Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.

- Run the engine in.

Running in the engine

6.2

- During the running-in phase, do not exceed the specified engine speed and engine performance.

Guideline

Maximum engine speed

During the first: 1,000 km (621.4 mi)

6,000 rpm

After the first: 1,000 km (621.4 mi)

7,800 rpm

PREPARING FOR USE

- Avoid fully opening the throttle!

Loading the vehicle

6.3

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 incorrect mounting of suitcase and/or tank rucksack.

- Mount and secure 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 baggage

130 km/h (80.8 mph)

Warning

Danger of accidents Risk of breakage of suitcase system.

- If you have fitted suitcases on your motorcycle, read 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 distance with excessive payload.

- Adapt your speed according to your payload.

PREPARING FOR USE

Warning

Danger of accidents Unstable handling characteristics due to slipped baggage.

- Check the way your baggage is fixed regularly.

Warning

Danger of burns 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 carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu-

tion between the front and rear wheels.

- Do not exceed the overall maximum permitted weight and the axle loads.

Guideline

Maximum permissible overall weight

350 kg (772 lb.)

Maximum permissible front axle load

150 kg (331 lb.)

Maximum permissible rear axle load

200 kg (441 lb.)

RIDING INSTRUCTIONS

Performing checks and vehicle care when preparing for use

7.1

Info

Before each use, check the state and roadworthiness of the vehicle.

Make sure that the vehicle is in perfect technical condition before use.

- Check the engine oil level. ( p. 122)

- Check the front brake fluid level. ( p. 78)

- Check the rear brake fluid level. ( p. 83)

- Check the front brake linings. ( p. 80)

- Check the rear brake linings. ( p. 85)

- Check the brake system function.

- Check the coolant level. ( p. 114)

- Check the chain for dirt. ( p. 66)

- Check the chain tension. ( p. 68)

- Check the tire condition. ( p. 94)

- Check the tire air pressure. ( p. 95)

- Check that all controls are correctly adjusted and free to move.

- Check that the electrical equipment is functioning correctly.

- Check that baggage is correctly secured.

- Sit on the motorcycle and check the rear mirror setting.

- Check the fuel level.

RIDING INSTRUCTIONS

Starting

7.2

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.

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 of the engine.

- Always warm up the engine at low engine speeds.

- Turn the emergency OFF switch to the position

– Switch on the ignition by turning the ignition key to position ON

After you switch on the ignition, you can hear the fuel pump working for about 2

seconds. At the same time, the function test of the combination instrument is run.

- Shift gear to neutral.

The green idling speed indicator lamp N lights up.

- Press the electric starter button

B00103-10

RIDING INSTRUCTIONS

Info

Do not press the electric starter button until the function test of the combination

instrument is finished.

When starting, 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 at least 5 seconds before

trying again.

This motorcycle is equipped with a safety start system. You can only start the

engine if the gearbox is in neutral or if the clutch is pulled when a gear is

engaged. If the side stand is folded out and you shift into gear and release the

clutch, the engine stops.

- Take the weight off the side stand and swing it back up with your foot as far as it will

go.

Starting off

7.3

- Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.

Shifting, riding

7.4

Warning

Danger of accidents Abrupt load alterations can cause the vehicle to get out of control.

- Avoid abrupt load alterations and sudden braking actions, and adapt your speed to the road conditions.

Warning

Danger of accidents If you change down at high engine speed, the rear wheel can lock up.

- Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up.

RIDING INSTRUCTIONS

Warning

Danger of accidents Malfunctions caused by incorrect ignition 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 capable of sitting correctly on the passenger seat.

- The passenger must hold on to the rider or the handrails and place his feet on the passenger footrests. Note the regulations

governing the minimum age of passengers in your country.

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 road

grip is ensured.

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 (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved

until the tires have been run in.

RIDING INSTRUCTIONS

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 fixed regularly.

Warning

Danger of accidents Lack of roadworthiness.

- After a fall, check the vehicle 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 cool down and check the

coolant level in the radiator, and top up if necessary. If you continue with the coolant temperature warning lamp alight, you may have

engine failure.

Info

If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.

RIDING INSTRUCTIONS

When conditions allow (incline, road situation, etc.), you can shift into a higher gear.

–

Release the throttle while simultaneously pulling the clutch lever, shift into the next

gear, release the clutch and open the throttle.

Info

You can see the positions of the 6 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.

The operating temperature is reached when 5 bars of the temperature indicator

light up.

600484-11

After reaching maximum speed by fully opening the throttle grip, turn the throttle back

so it is ¾ open. This will barely reduce the speed but fuel consumption will be consid-

erably lower.

Accelerate only up to a speed suitable for the road surface and weather conditions.

When traveling in bends, do not shift, and accelerate very carefully.

To shift down, brake if necessary and close the throttle at the same time.

–

Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open

the throttle or shift again.

If the engine stalls (e.g. at a crossroads), just pull the clutch lever and press the starter

button. You do not have to shift into neutral.

Switch off the engine if you expect to be standing for a long time.

–

Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine

and the cooling system.

Ride with a lower engine speed instead of with a high engine speed and a slipping

clutch.

If the FI warning lamp (MIL) lights up during a trip, stop immediately. When you shift to

neutral, the FI warning lamp (MIL) starts to flash.

RIDING INSTRUCTIONS

Info

From the flashing rhythm, you can derive a two-digit number, the so-called blink

code. The blink code tells you which component has a fault.

Braking

7.5

Warning

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 system 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.

- Take the longer stopping distance into account when carrying a passenger and baggage.

RIDING INSTRUCTIONS

Warning

Danger of accidents Delayed brake action on salted roads.

- There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the

deposits from the discs by carefully applying the brakes.

- To brake, release the throttle and operate the front and rear brakes simultaneously.

- On sandy, wet or slippery surfaces, use the rear brake.

- Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.

- On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine. In

this way, you have to brake far less and the brakes do not overheat.

Stopping, parking

7.6

Warning

Risk of misappropriation Usage by unauthorized persons.

- Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. If you leave the

vehicle, lock the steering and remove the ignition key.

Warning

Danger of burns Some vehicle components become very hot when the vehicle is operated.

- Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. 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.

RIDING INSTRUCTIONS

- Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being

run. Always let the vehicle cool first.

Note

Material damage Damage and destruction of components by excessive load.

- The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand

only. The side stand and/or the frame could be damaged and the motorcycle could fall over.

- Brake the motorcycle.

- Shift gear to neutral.

- Switch off the ignition by turning the ignition key to position OFF

Info

If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock, power

continues to flow to most power consumers and the battery will discharge. You should therefore always switch off the engine

with the ignition key - the emergency OFF switch is intended for emergencies only.

- Park the motorcycle on a firm surface.

- Swing the side stand forward with your foot as far as it will go and lean the vehicle on it.

- Lock the steering by turning the handlebar fully to the left, pressing down the ignition key to position and turning it to position

To make the steering lock engage more easily, move the handlebar a little to the left and right. Remove the ignition key.

Refueling

7.7

Danger

Fire hazard Fuel is highly flammable.

- Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is

spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

- Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

RIDING INSTRUCTIONS

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

- Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately

with water and contact a 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 will be glad to 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.

Info

This motorcycle is equipped with a regulated catalytic converter. Leaded fuel will destroy the catalytic converter. You should there-

fore use unleaded fuel only.

RIDING INSTRUCTIONS

- Switch off the engine.

- Open the filler cap. ( p. 32)

- Fill the fuel tank with fuel up to measurement .

Guideline

Measurement 

20 mm (0.79 in)

Total fuel tank

12 l (3.2 US gal)

Super unleaded (ROZ 95 / RON 95 /

capacity, approx.

PON 91) ( p. 161)

400405-10

- Close the filler cap. ( p. 33)

- 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 display mode.

Info

If you do not press the SET button , the reset takes place automatically after

about three minutes.

400882-10

SERVICE PLAN

8.1

Service schedule

K10N

K75A

K150A

K300A

Check that the electrical equipment is functioning correctly.

•

Read out the fault memory using the KTM diagnostics tool. x

•

Check the measured service values with the KTM diagnostics tool. x

•

Change the engine oil and filter, clean the oil screens. x ( p. 123)

•

Check the front brake linings. ( p. 80)

•

Check the rear brake linings. ( p. 85)

•

Check the brake discs. ( p. 77)

•

Check the brake lines for damage and leakage.

•

Check the rear brake fluid level. ( p. 83)

•

Check the free travel of the foot brake lever. ( p. 81)

•

Lubricate the linkage of the rear wheel suspension. x

•

Check that the shock absorber and fork are leak tight. If necessary and depending on use, service

•

the fork and shock absorber.

Check the swingarm bearing. x

•

Check the wheel bearing for play. x

•

Check the tire condition. ( p. 94)

•

Check the tire air pressure. ( p. 95)

•

Check the spoke tension. ( p. 96)

•

Check for rim run-out. x

•

Check the chain, rear sprocket, engine sprocket and chain guide. ( p. 71)

•

Check the chain tension. ( p. 68)

•

Grease all moving parts (e.g. side stand, hand lever, chain, ...) and check for smooth operation. x

•

SERVICE PLAN

K10N

K75A

K150A

K300A

Clean the dust boots of the fork legs.

•

Check the front brake fluid level. ( p. 78)

•

Bleed the fork legs. ( p. 63)

•

Check the steering head bearing play.

•

Change the spark plug.

•

Check the valve clearance. x

•

Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and

•

incorrect routing. x

Check the antifreeze and coolant level. ( p. 112)

•

Check the cables for damage and routing without sharp bends. x

•

Check that the throttle cables are undamaged, routed without sharp bends and set correctly.

•

Change the air filter. Clean the air filter box. x

•

Check the fuel pressure. x

•

Check the CO adjustment with the KTM diagnostics tool. x

•

Check/rectify the fluid level of the hydraulic clutch. ( p. 76)

•

Check the screws and nuts for tightness. x

•

Change the coolant. x

•

Change the front brake fluid. x

•

Change the rear brake fluid. x

•

Check the clutch. x

•

SERVICE PLAN

K10N

K75A

K150A

K300A

Check the headlight setting.

•

Check that the radiator fan is functioning properly. x

•

Final check: Check the vehicle for roadworthiness and take a test ride.

•

Read out the fault memory using the KTM diagnostics tool after a test ride. x

•

Make the service entry in KTM DEALER.NET and in the 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

TUNING THE CHASSIS

Fork/shock absorber

9.1

The fork and the shock absorber offer many options of adapting the chassis to your riding

style and the payload.

Info

To help you adapt the vehicle, we have summarized our findings in Table . You

can find the table on the underside of the seat.

These adjustments should be understood as a guideline and should always be the basis

of your own personal chassis adaptation. Do not change the adjustments at random or by

100242-01

more than ± 40%, since otherwise the riding characteristics could deteriorate, particularly

at high speeds.

Adjusting the compression damping of the fork

9.2

Info

The hydraulic compression damping determines the fork suspension behavior.

- Turn adjusting screws  clockwise until they stop.

Info

The adjusting screws are located at the bottom end of the fork legs.

Make the same adjustment on both fork legs.

- Turn back counterclockwise by the number of clicks corresponding to the fork type.

600490-10

TUNING THE CHASSIS

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.

Adjusting the rebound damping of the fork

9.3

Info

The hydraulic rebound damping determines the fork rebound behavior.

- Turn adjusting screws  clockwise until they stop.

Info

The adjusting screws are located at the top end of the fork legs.

Make the same adjustment on both fork legs.

- Turn back counterclockwise by the number of clicks corresponding to the fork type.

100244-10

TUNING THE CHASSIS

Guideline

Rebound damping

Comfort

15 clicks

Standard

10 clicks

Sport

5 clicks

Full payload

5 clicks

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damping.

Compression damping of the shock absorber

9.4

The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.

High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.

The high-speed setting, for example, has an effect on the landing after a jump: the rear wheel suspension compresses more 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 low-speed range and vice versa.

Adjusting the low-speed compression damping of the shock absorber

9.5

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

be glad to help.)

TUNING THE CHASSIS

Info

The low-speed setting can be seen during the slow to normal compression of the shock absorber.

- Turn the adjusting screw  clockwise with a screwdriver up to the last perceptible

click.

Info

Do not loosen nut !

- Turn back counterclockwise by the number of clicks corresponding to the shock

absorber type.

Guideline

100245-10

Compression damping, low-speed

Comfort

20 clicks

Standard

15 clicks

Sport

10 clicks

Full payload

10 clicks

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damping.

Adjusting the high-speed compression damping of the shock absorber

9.6

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

be glad to help.)

TUNING THE CHASSIS

Info

The high-speed setting can be seen during the fast compression of the shock absorber.

- Turn adjusting screw  all the way clockwise using a socket wrench.

Info

Do not loosen nut !

- Turn back counterclockwise the number of turns corresponding to the shock absorber

type.

Guideline

Compression damping, high-speed

100246-10

Comfort

1.5 turns

Standard

1 turn

Sport

0.5 turn

Full payload

0.5 turn

Info

Turn clockwise to increase damping, turn counterclockwise to reduce suspension

damping.

Adjusting the rebound damping of the shock absorber

9.7

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

be glad to help.)

SERVICE WORK ON THE CHASSIS

Raising the motorcycle with the front wheel stand

10.1

Note

Danger of damage The parked vehicle may roll away or fall over.

- Always place the vehicle on a firm and even surface.

- Raise the motorcycle with the rear wheel stand. ( p. 62)

- Move 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.

600493-01

Taking the motorcycle off of the front wheel stand

10.2

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 front wheel stand.

SERVICE WORK ON THE CHASSIS

Raising the motorcycle with the rear wheel stand

10.3

Note

Danger of damage The parked vehicle may roll away or fall over.

- Always place the vehicle on a firm and even surface.

- Insert the adapter into the rear wheel stand and screw into the swingarm on both sides.

Adapter (61029055110)

Rear wheel stand (61029055100)

- Position the motorcycle upright, align the stand and raise the motorcycle.

600492-01

Taking the motorcycle off of the rear wheel stand

10.4

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 rear wheel stand and lean the vehicle on the side stand.

SERVICE WORK ON THE CHASSIS

Bleeding the fork legs

10.5

- Lean the motorcycle on the side stand.

- Remove bleeder screws  briefly.

Any excess pressure escapes from the interior of the fork.

- Mount and tighten bleeder screws.

Info

Carry out this action on both fork legs.

100844-10

Removing the seat

10.6

- Pull on strap  and raise the rear of the seat at the same time.

- Pull back the seat and lift it off.

100230-10

SERVICE WORK ON THE CHASSIS

Mounting the seat

10.7

- Hook slot  of the seat onto screw , press the rear downward and at the same time

push it forward.

- Push locking pin  into lock housing  and push the back of the seat down until the

locking pin locks in place with an audible click.

- Finally, check that the seat is correctly mounted.

100276-10

10.8

Removing the air filter x

- Remove the seat. ( p. 63)

- Remove screws . Remove filter box top .

100285-10

SERVICE WORK ON THE CHASSIS

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.

- Remove air filter .

100286-10

10.9

Installing the air filter x

- Clean the air filter box.

- Mount air filter .

Info

The air filter must lie flush against the air filter box along the entire sealing sur-

face .

If the air filter is not correctly mounted, dust and dirt can penetrate into the

engine and can cause damage.

- Hook filter box top  into the front of the air filter box and swing down.

100287-10

SERVICE WORK ON THE CHASSIS

- Mount and tighten screws .

Guideline

Screw, air filter box top

2 Nm (1.5 lbf ft)

– Mount the seat. ( p. 64)

100285-11

10.10

Checking the chain for dirt

- Check the chain for heavy soiling.

» If the chain is very dirty:

- Clean the chain. ( p. 66)

400678-01

Cleaning the chain

10.11

Warning

Danger of accidents Oil or grease on the tires reduces their grip.

- Remove oil and grease with a suitable cleaning material.

SERVICE WORK ON THE CHASSIS

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 be disposed of as stipulated in applicable regulations.

Info

The service life of the chain depends largely on its maintenance.

- Clean the chain regularly.

- Rinse off loose dirt with a soft jet of water.

- Remove old grease remains with chain cleaner.

Chain cleaner ( p. 162)

- After drying, apply chain spray.

Chain lube for road use ( p. 162)

400725-01

SERVICE WORK ON THE CHASSIS

Checking the chain tension

10.12

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 the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or

the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if necessary.

- Lean the motorcycle on the side stand.

- Shift gear to neutral.

- Push the chain upward at a distance  from the chain sliding guard and determine the

chain tension .

Info

The upper chain section  must be taut.

Chain wear is not always even, so you should repeat this measurement at differ-

ent chain positions.

Chain tension

5 mm (0.2 in)

Distance to chain sliding guard

30 mm (1.18 in)

» If the chain tension does not meet specifications:

- Adjust the chain tension. ( p. 69)

100249-10

SERVICE WORK ON THE CHASSIS

Adjusting the chain tension

10.13

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 the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or

the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if necessary.

- Check the chain tension. ( p. 68)

SERVICE WORK ON THE CHASSIS

- Loosen nut .

- Loosen nuts .

- Adjust the chain tension by turning adjusting screws  on the left and right.

Guideline

Chain tension

5 mm (0.2 in)

Turn the left and right adjusting screws  so that the markings on the left and right

chain adjusters  are in the same position relative to the reference 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 this setting at different

chain positions.

- Tighten nuts .

- Make sure that the chain adjusters  are installed correctly on adjusting screws .

- Tighten nut .

Guideline

600597-10

Nut, rear wheel spindle

M25x1.5

90 Nm

(66.4 lbf ft)

Info

The wide adjustment range of the chain adjusters (30 mm (1.18 in)) enables

different secondary transmissions with the same chain length.

The chain adjusters  can be turned through 180°.

SERVICE WORK ON THE CHASSIS

10.14

Check the chain, rear sprocket, engine sprocket and chain guide

- Raise the motorcycle with the lift stand.

- Shift gear to neutral.

- Check the rear sprocket and engine sprocket for wear.

» If the rear sprocket and engine sprocket are worn:

- Replace the rear sprocket or engine sprocket. x

Info

The engine sprocket, rear sprocket and chain should always be replaced

together.

100132-10

SERVICE WORK ON THE CHASSIS

- Pull on the upper section of the chain with the specified weight .

Guideline

Weight of chain wear measurement

15 kg (33 lb.)

– Measure distance  of 18 chain links in the lower chain section.

Info

Chain wear is not always even, so you should repeat this measurement at differ-

ent chain positions.

Maximum distance  at the longest

272 mm (10.71 in)

chain section

» If the 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.

16 17 18

400987-10

SERVICE WORK ON THE CHASSIS

- Check the chain sliding guard for wear.

» If the lower edge of the chain pins is in line with or below the chain sliding guard:

- Replace the chain sliding guard. x

– Check that the chain sliding guard is firmly seated.

» If the chain sliding guard is loose:

- Tighten the chain sliding guard.

Guideline

Screw, chain sliding

6 Nm

Loctite^® 243™

guard

(4.4 lbf ft)

401170-01

SERVICE WORK ON THE CHASSIS

- Check the chain sliding piece for wear.

» If the lower edge of the chain pins is in line with or below the chain sliding piece:

- Change the chain sliding piece. x

– Check that the chain sliding piece is firmly seated.

» If the chain sliding piece is loose:

- Tighten the chain sliding piece.

Guideline

Screw, chain sliding piece

15 Nm

(11.1 lbf ft)

401171-01

- Check the chain guide for wear.

Info

Wear is visible on the front of the chain guide.

» If the light part of the chain guide is worn:

- Change the chain guide. x

400985-01

SERVICE WORK ON THE CHASSIS

- Check that the chain guide is firmly seated.

» If the chain guide is loose:

- Tighten the chain guide.

Guideline

Remaining screws, chassis

10 Nm

(7.4 lbf ft)

- Remove the motorcycle from the lift stand.

601273-10

Adjusting basic position of clutch lever

10.15

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 adjusting screw by hand only, and do not apply any force.

Do not make any adjustments while riding!

- Adjust the basic setting of the clutch lever to your hand size by turning adjusting

screw .

- When adjusting the clutch lever make sure that there is a minimum clearance to other

parts of the vehicle.

Guideline

Minimum clearance

5 mm (0.2 in)

100282-10

SERVICE WORK ON THE CHASSIS

Checking/rectifying the fluid level of the hydraulic clutch

10.16

Info

The fluid level rises with increasing wear of the clutch lining disc.

Do not use brake fluid.

- 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 under top level of container

4 mm (0.16 in)

» If the level of the coolant does not meet specifications:

- Correct the fluid level of the hydraulic clutch.

Hydraulic fluid (15) ( p. 160)

100281-10

- Position the cover with the membrane. Mount and tighten the screws.

BRAKES

Adjusting the basic position of the hand brake lever

11.1

- Adjust the basic setting of the hand brake lever to your hand size by turning adjusting

wheel .

Info

Pull the brake lever forwards and turn the adjusting wheel.

Do not make any adjustments while riding!

600598-10

Checking the brake discs

11.2

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.)

- Check the thickness of the front and rear brake discs in several places to ensure that it

conforms to measurement .

Info

Wear reduces the thickness of the brake disc at the contact surface  of the

brake disc.

Brake discs - wear limit

Front

4.0 mm (0.157 in)

100135-10

Rear

4.5 mm (0.177 in)

BRAKES

» If the brake disc thickness is less than the specified value:

- Replace the brake disc.

- Check the front and rear brake discs for damage, cracks, and deformation.

» If damage, cracks, or deformation are visible on the brake disc:

- Replace the brake disc.

Checking the front brake fluid level

11.3

Warning

Danger of accidents Failure of the brake system.

- If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check

the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

Warning

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.)

- Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

- Check the brake fluid level in the viewer .

» If the brake fluid level is below the MIN mark:

- Add front brake fluid. x ( p. 79)

600603-10

BRAKES

Adding front brake fluid x

11.4

Warning

Danger of accidents Failure of the brake system.

- If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check

the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

Warning

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 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, 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 designed for DOT 5 brake

fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!

Use only clean brake fluid from a sealed container.

BRAKES

- Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

- Remove screws .

- Remove cover  with membrane .

- Add brake fluid to level .

Guideline

Measurement of 

5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 ( p. 158)

100254-10

- Position the cover with the membrane. Mount and tighten the screws.

Info

Clean up overflowed or spilt brake fluid immediately with water.

Checking the front brake linings

11.5

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 greatly

reduced and the brake discs are rendered unserviceable. Check the brake linings regularly.

BRAKES

- Check the brake linings for minimum thickness .

Minimum thickness 

≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

- Change the front brake linings. x

– Check the brake linings for damage and cracking.

» If there is wear or tearing:

- Change the front brake linings. x

600625-10

Checking the free travel of foot brake lever

11.6

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 free travel on foot brake lever according to specifications.

- Move the foot brake lever back and forth between the end stop and the contact to the

foot brake cylinder piston and check free travel .

Guideline

Free travel at foot brake lever

3… 5 mm (0.12… 0.2 in)

Info

You will know that contact has been made with the foot brake cylinder piston

when there is increased resistance when you activate the foot brake lever.

600599-10

» If the free travel does not meet specifications:

- Adjust the basic position of the foot brake lever. x ( p. 82)

BRAKES

Adjusting the basic position of the foot brake lever x

11.7

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 free travel on foot brake lever according to specifications.

- Remove screws  on foot brake cylinder .

- To adjust the basic position of the foot brake lever individually, loosen nut  and turn

screw  accordingly.

Info

The range of adjustment is limited. The screw must be screwed into the footrest

bracket by at least four turns.

- Position foot brake cylinder  so that the foot brake lever has the necessary free travel.

Hold screws  in place and tighten the nuts.

Guideline

Nut, foot brake cylinder screw

10 Nm (7.4 lbf ft)

– Check the free travel of the foot brake lever. ( p. 81)

- Tighten nut .

600639-10

BRAKES

Checking rear brake fluid level

11.8

Warning

Danger of accidents Failure of the brake system.

- If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check

the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

Warning

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.)

- Stand the vehicle upright.

- Check the brake fluid level in the brake fluid reservoir.

» If the fluid level reaches the MIN marking :

- Add rear brake fluid. x ( p. 83)

100258-10

Adding rear brake fluid x

11.9

Warning

Danger of accidents Failure of the brake system.

- If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check

the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

BRAKES

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 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, 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 designed for DOT 5 brake

fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!

Use only clean brake fluid from a sealed container.

BRAKES

- Stand the vehicle upright.

- Remove screw cap  with the washer and membrane .

- Add brake fluid to the MAX mark.

Brake fluid DOT 4 / DOT 5.1 ( p. 158)

- Mount the screw cap with the washer and membrane.

Info

Clean up overflowed or spilt brake fluid immediately with water.

100259-10

Checking the rear brake linings

11.10

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 greatly

reduced and the brake discs are rendered unserviceable. Check the brake linings regularly.

WHEELS, TIRES

Removing front wheel x

12.1

- Raise the motorcycle with the rear wheel stand. ( p. 62)

- Raise the motorcycle with the front wheel stand. ( p. 61)

- Remove screws  and spacers .

- Press back the brake linings with a light lateral tilting of the brake caliper on the brake

disc. Pull the brake caliper carefully back from the brake disc and hang it to one side.

Info

Do not pull the handbrake lever when the brake caliper is removed.

600621-10

- Loosen screws  and .

- Unscrew screw  about 6 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 such a way that the brake disc is not damaged.

600622-10

- Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the

fork.

WHEELS, TIRES

- Remove distance bushings .

600626-11

Installing the front wheel x

12.2

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.

- Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:

- Replace the wheel bearing. x

– Clean and grease the shaft seal rings and bearing surface of the distance bushings .

Long-life grease ( p. 163)

- Insert the spacers.

600626-10

WHEELS, TIRES

Clean and grease the thread of the wheel spindle and screw .

Long-life grease ( p. 163)

Lift the front wheel into the fork, position it, and insert the wheel spindle. Mount and

tighten screw .

Guideline

Screw, front wheel spindle

M24x1.5

40 Nm

(29.5 lbf ft)

Position the brake caliper and check that the brake linings are seated correctly.

600621-11

–

Position spacers . Mount screws  but do not tighten.

–

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 caliper straightens.

Fully tighten screws .

Guideline

Screw, front brake caliper

M10x1.25

45 Nm

Loctite^® 243™

(33.2 lbf ft)

Remove the fixation of the hand brake lever.

WHEELS, TIRES

- Take the motorcycle off of the front wheel stand. ( p. 61)

- Pull the front wheel brake and push down hard on the fork several times to align the

fork legs.

- Tighten screws .

Guideline

Screw, fork stub

15 Nm

(11.1 lbf ft)

- Take the motorcycle off of the rear wheel stand. ( p. 62)

600490-11

Removing rear wheel x

12.3

- Raise the motorcycle with the rear wheel stand. ( p. 62)

- Press the brake caliper by hand on to the brake disc in order to press back the brake

piston.

- Remove nut . Remove chain adjuster .

- Holding the rear wheel, withdraw the wheel spindle .

100267-10

WHEELS, TIRES

- Push the rear wheel forwards as far as possible and take the chain off the rear sprocket.

Warning

Danger of accidents Reduced braking efficiency caused by damaged brake

discs.

- Always lay the wheel down in such a way that the brake disc is not damaged.

- Take the rear wheel out of the swing arm.

600627-01

Info

Do not operate the foot brake when the rear wheel is removed.

Installing the rear wheel x

12.4

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

Danger of accidents No braking effect when operating the rear brake.

- After installing the rear wheel, always operate the foot brake until the pressure point is reached.

- Check the rear hub rubber dampers. x ( p. 93)

WHEELS, TIRES

Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:

- Replace the wheel bearing. x

–

Remove the bushing . Clean and grease the roll surfaces of the bushing and the shaft

seal ring .

Long-life grease ( p. 163)

Clean and grease the thread of the wheel spindle and nut .

600628-10

Long-life grease ( p. 163)

Install the rubber damper 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.

Push the rear wheel forward as far as possible and lay the chain on the rear sprocket.

–

Mount the wheel spindle, chain adjusters and nuts.

Guideline

In order that the rear wheel is correctly aligned, the markings on the left and right

chain adjusters must be in the same position relative to the reference marks .

Info

Mount the left and right chain adjusters  in the same position.

100270-10

- Tighten nut .

Guideline

Nut, rear wheel spindle

M25x1.5

90 Nm

(66.4 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.

WHEELS, TIRES

- Take the motorcycle off of the rear wheel stand. ( p. 62)

Checking the rear hub rubber dampers x

12.5

Info

The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during

operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged.

- Remove the rear wheel. x ( p. 90)

- Check bearing .

» If the bearing is damaged or worn:

- Replace the bearings. x

– Check rubber dampers  of the rear hub for damage and wear.

» If the rubber dampers of the rear hub are damaged or worn:

- Change all rubber dampers in the rear hub.

600623-10

- Lay the rear wheel on a workbench with the rear sprocket facing upwards and insert the

wheel spindle in the hub.

- To check play , hold the rear wheel tight and try to rotate the rear sprocket.

Info

Measure the play on the outside of the rear sprocket.

Play in rubber dampers, rear wheel

≤ 5 mm (≤ 0.2 in)

» If play  is larger than the specified value:

600624-10

WHEELS, TIRES

- Change all rubber dampers in the rear hub.

- Install the rear wheel. x

(

p. 91)

Checking the tire condition

12.6

Warning

Danger 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 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 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 (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved

until the tires have been run in.

Info

The type, condition and air pressure of the tires all have a major impact on the handling characteristics of the motorcycle.

Worn tires have a negative effect on riding behavior, especially on wet surfaces.

WHEELS, TIRES

- 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 regulations concerning the minimum tread depth.

Minimum tread depth

≥ 2 mm (≥ 0.08 in)

400602-10

» If the tread depth is less than the minimum permissible depth:

- Change the tires.

- Check the tire age.

Info

The tire's date of the manufacture is usually part of the tire markings and is

indicated by the last four digits of the DOT marking. The first two digits refer to

the week of manufacture and last two 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 5 years old:

- Change the tires.

Checking the tire air pressure

12.7

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.

WHEELS, TIRES

- Remove dust cap.

- Check tire air pressure when tires are cold.

Tire air pressure, solo

Front

2.0 bar (29 psi)

Rear

2.0 bar (29 psi)

Tire air pressure with passenger / fully loaded

Front

2.0 bar (29 psi)

400695-01

Rear

2.2 bar (32 psi)

» If the tire pressure does not meet specifications:

- Correct tire pressure.

- Mount dust cap.

Checking the spoke tension

12.8

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 causes wheel imbalance and rapidly leads to more loose spokes.

If the spokes are too tight, they can break due to local overload.

Check the spoke tension regularly, especially on a new motorcycle.

ELECTRICAL SYSTEM

Removing the battery x

13.1

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 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.

- Switch off all power consumers and switch off the engine.

- Remove the seat. ( p. 63)

- Disconnect the negative (minus) cable of the battery.

- Pull off the plug connector  upwards.

- Remove screws .

- Pull the retaining bracket  of the battery forward and remove it.

- Take off the positive pole cover .

- Disconnect the positive (plus) cable of the battery.

- Push the wiring harness to the side and pull the battery out of the battery rack.

100277-10

Info

Never operate the motorcycle with a discharged battery or without a battery. In

both cases, electrical components and safety devices can be damaged. The vehi-

cle is therefore no longer roadworthy.

ELECTRICAL SYSTEM

Installing the battery x

13.2

- Slide the battery into the battery rack.

Info

The battery terminals must be at the rear.

- Attach the positive cable and mount positive terminal cover .

- Position retaining bracket .

- Mount and tighten screws .

Guideline

100277-11

Remaining screws, chassis

10 Nm (7.4 lbf ft)

– Plug in connector .

- Attach the minus cable .

- Mount the seat. ( p. 64)

- Set the clock. ( p. 28)

Recharging the battery x

13.3

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 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.

ELECTRICAL SYSTEM

100

Warning

Environmental hazard Battery parts and acid are harmful to the environment.

- Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner.

Give the battery to your KTM dealer or to a recycling center that accepts used batteries.

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

Even when there is no load on the battery, it still loses power steadily.

The charge state and the type of charge are very important for the service life of 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 an extended period, it will become over-discharged and sulfate, destroying the battery.

The battery is maintenance-free, which means that the acid level does not need to be checked.

- Switch off all power consumers and switch off the engine.

- Remove the battery. x

(

p. 98)

ELECTRICAL SYSTEM

101

- Connect the battery charger to the battery. Switch on the battery charger.

Battery charger (58429074000)

You can also use the battery charger to test rest potential and start potential of the bat-

tery, and to test the alternator. With this device, you cannot overcharge the battery.

Info

Never remove lid .

Charge the battery with a maximum of 10% of the capacity specified on the bat-

tery housing .

- Switch off and disconnect the charger after charging.

Guideline

The charge current, charge voltage and charge time must not be exceeded.

Charge the battery regularly when the

3 months

motorcycle is not in use

- Install the battery. x ( p. 99)

100151-10

Changing the main fuse

13.4

Warning

Fire hazard The electrical system can be overloaded if the wrong fuses are used.

- Use only fuses with the prescribed amperage. Never by-pass or repair fuses.

ELECTRICAL SYSTEM

102

Info

The main fuse protects all power consumers in the vehicle. It is in the housing of the starter relay next to the battery.

- Switch off all power consumers and switch off the engine.

- Remove the seat. ( p. 63)

- Remove protection covers .

600604-10

- Remove a defective main fuse  with needle nose pliers.

- Install a new main fuse.

Fuse (58011109130) ( p. 150)

Info

A reserve fuse  is located in the starter relay.

- Check that the electrical equipment is functioning properly.

600605-10

- Mount the protection covers.

- Mount the seat. ( p. 64)

- Set the clock. ( p. 28)

ELECTRICAL SYSTEM

104

- Remove the defective fuse.

Guideline

Fuse 1 - 10 A - ignition, combination instrument

Fuse 2 - 10 A - clock, ignition (EFI control unit)

Fuse 3 - 10 A - throttle valve control unit

Fuse 4 - 10 A - fuel pump

Fuse 5 - 10 A - radiator fan

Fuse 6 - 10 A - horn, brake light, turn signal

Fuse 7 - 15 A - high beam, low beam, parking light, tail light, license plate lamp

Fuse 8 - 10 A - for supplementary equipment (accessories connected with ignition

switch)

Fuse 9 - 10 A - for accessories (permanent positive)

Fuse 10 - not used

Fuse SPARE - 10 A/15 A - spare fuses

Info

A defective fuse is indicated by a burned-out fuse wire .

600606-10

Warning

Fire hazard The electrical system can be overloaded if the wrong fuses are

used.

- Use only fuses with the prescribed amperage. Never by-pass or repair fuses.

- Replace with a spare fuse of the right rating.

Fuse (75011088010) ( p. 150)

Fuse (75011088015) ( p. 150)

ELECTRICAL SYSTEM

105

Tip

Put a new spare fuse in the fuse box for future use if needed.

- Check the function of power consumers.

- Close the fuse box cover.

- Mount the seat. ( p. 64)

13.6

Removing the headlight mask with the headlight

- Switch off all power consumers and switch off the engine.

- Cover the fender with a cloth to protect it from damage.

- Remove screws  on the left and right.

- Tip the headlight mask forward and pull it off in an upward direction.

100296-11

- Disconnect the connectors of turn signals  and headlight .

- Put down the headlight mask.

100294-10

ELECTRICAL SYSTEM

107

- Position groove  on counterpiece .

700543-01

- Position brake-hose guide . Mount and tighten screws .

Guideline

Remaining screws, chassis

10 Nm (7.4 lbf ft)

100296-10

Changing the headlight bulb

13.8

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 headlight mask with the headlight. ( p. 105)

ELECTRICAL SYSTEM

108

- Pull off connector .

- Take off rubber cap  of the headlight bulb.

600610-10

- Detach spring bar .

- Remove headlight bulb .

- Insert a new headlight bulb into the headlight housing.

Headlight (H4 / socket P43t) ( p. 150)

- Fix the headlight bulb in the headlight using the spring bar.

- Replace the rubber cap. Attach the connector.

- Install the headlight mask with the headlight. ( p. 106)

600611-10

Changing the parking light bulb

13.9

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 headlight mask with the headlight. ( p. 105)

ELECTRICAL SYSTEM

109

- Remove rubber cap .

600610-12

- Pull bulb socket  out of the reflector.

- Pull parking light bulb  out of the bulb socket.

- Insert a new parking light bulb in the bulb socket.

Parking light (W5W / socket W2.1x9.5d) ( p. 150)

- Insert the bulb socket in the reflector.

- Insert the rubber cap.

- Install the headlight mask with the headlight. ( p. 106)

600612-10

Changing the turn signal bulb

13.10

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.

ELECTRICAL SYSTEM

110

- Remove the screw on the rear of the turn signal housing.

- Tilt headlamp diffuser  forward carefully and take it off.

- Press the turn signal bulb carefully into the socket, turn it counterclockwise by about

30°, and take it out of the socket.

Info

Do not touch the reflector with your fingers, and keep it free from grease.

- Press the new turn signal bulb carefully into the socket and turn it clockwise until it

100160-10

stops.

Turn signal (RY10W / socket BAU15s) ( p. 150)

- Position the diffuser.

- Insert the screw and turn it counterclockwise first until it engages in the thread. Tighten

the screw slightly.

- Check the turn signal system function.

Checking the low beam headlight adjustment

13.11

- Stand the vehicle upright on a horizontal surface in front of a light wall and make a

mark at the height of the center of the low beam headlight.

- Make another mark at a distance  under the first mark.

Guideline

Distance 

5 cm (2 in)

– Position the vehicle vertically at a distance  in front of the wall and switch on the low

beam.

Guideline

400726-10

Distance 

5m(16ft)

ELECTRICAL SYSTEM

111

- The rider, with luggage and a passenger if applicable, now sits down on the motorcycle.

- Check the low beam headlight adjustment.

For a ready-to-operate motorcycle with a rider, and with luggage and a passenger if

applicable, the light-dark boundary must lie exactly on the lower mark.

» If the boundary between light and dark does not meet specifications:

- Adjust the light range of the low beam headlight.

Adjusting the headlight range

13.12

- Check the headlight setting.

- Turn adjusting screw  to adjust the headlight range.

Guideline

For a motorcycle with rider, the light/dark boundary must be exactly on the lower

mark (made in: Checking headlight adjustment).

Info

Turn clockwise to increase the headlight range; turn counterclockwise to reduce

the headlight range.

If you have a heavy payload, you will need to correct the headlight range.

800084-10

COOLING SYSTEM

112

Cooling system

14.1

The water pump  in the engine forces the coolant to flow.

The pressure in the cooling system resulting from heat is regulated by a valve in the radi-

ator cap . 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. This permits the specified coolant temperature without causing any malfunctions.

125 °C (257 °F)

600630-10

Cooling takes place by means of the air stream and a radiator fan , which is controlled by

a thermoswitch.

The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling

effect.

400407-10

Checking the antifreeze and coolant level

14.2

Warning

Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.

- Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine

and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

COOLING SYSTEM

113

Warning

Danger of poisoning 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.

Condition

Engine is cold.

- Stand the motorcycle on its side stand on a horizontal surface.

- Remove the cap of the compensating tank .

- Check antifreeze of coolant.

−25… −45 °C (−13… −49 °F)

» If the antifreeze of the coolant does not meet specifications:

- Correct the antifreeze of the coolant.

- Check the coolant level in the compensating tank.

100283-10

The coolant level must be within the range shown in the figure.

» If the coolant level does not meet specifications:

- Correct the coolant level.

Alternative 1

Coolant ( p. 158)

Alternative 2

Coolant (mixed ready to use) ( p. 158)

- Mount the cap of the compensating tank.

COOLING SYSTEM

114

Screw off the radiator cap .

–

Check antifreeze of coolant.

−25… −45 °C (−13… −49 °F)

» If the antifreeze of the coolant does not meet specifications:

- Correct the antifreeze of the coolant.

Check the coolant level in the radiator.

The radiator must be completely filled.

100284-10

» If the coolant level does not meet specifications:

- Correct the coolant level and find out the cause of the loss.

Alternative 1

Coolant ( p. 158)

Alternative 2

Coolant (mixed ready to use) ( p. 158)

Mount the radiator cap.

Checking the coolant level

14.3

Warning

Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.

- Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine

and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

COOLING SYSTEM

115

Warning

Danger of poisoning 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.

Condition

Engine is cold.

- Stand the motorcycle on its side stand on a horizontal surface.

- Check the coolant level in the compensating tank .

The coolant level must be within the range shown in the figure.

» If the coolant level does not meet specifications:

- Correct the coolant level.

Alternative 1

Coolant ( p. 158)

100283-10

Alternative 2

Coolant (mixed ready to use) ( p. 158)

- Screw off the radiator cap  and check the coolant level in the radiator.

The radiator must be completely filled.

» If the coolant level does not meet specifications:

- Correct the coolant level and find out the cause of the loss.

Alternative 1

Coolant ( p. 158)

100284-10

COOLING SYSTEM

116

Alternative 2

Coolant (mixed ready to use) ( p. 158)

- Mount the radiator cap.

Draining the coolant x

14.4

Warning

Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.

- Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine

and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

Warning

Danger of poisoning 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.

- Stand the motorcycle upright.

- Place a suitable container under the engine.

- Remove screw . Remove the radiator cap.

- Completely drain the coolant.

- Mount screw  with a new seal ring and tighten it.

Guideline

Plug, drain hole of water pump

M10x1

15 Nm

(11.1 lbf ft)

600616-10

COOLING SYSTEM

117

Filling the cooling system x

14.5

Warning

Danger of poisoning 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.

- Stand the motorcycle on its side stand on a horizontal surface.

- Remove radiator cap .

600618-10

- Refill the coolant.

Alternative 1

Coolant ( p. 158)

Alternative 2

Coolant (mixed ready to use) ( p. 158)

- Fill the radiator completely with coolant. Mount radiator cap .

600619-10

COOLING SYSTEM

118

- Remove the cap from compensating tank  and add coolant to the level shown in the

figure.

- Mount the cap of the compensating tank.

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

100283-11

exhaust extraction system.

- Start the engine and run it until the 5th bar of the temperature indicator lights up.

- Switch off the engine and allow it to cool down.

- After the engine has cooled down, check the coolant level in the radiator and in the

compensating tank again and add more coolant if necessary.

TUNING THE ENGINE

119

Checking the play in the throttle cable

15.1

Move the handlebar to the straight-ahead position. Move the throttle grip backwards

and forwards to ascertain the play in the throttle cable.

Throttle cable play

3… 5 mm (0.12… 0.2 in)

» If the throttle cable play does not meet specifications:

- Adjust the play in the throttle cable. x ( p. 120)

Danger

Danger of poisoning Exhaust gases are poisonous and inhaling them may result

400192-10

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 the entire steer-

ing range.

The idle speed must not change.

» If the idle speed changes:

- Adjust the play in the throttle cable. x ( p. 120)

TUNING THE ENGINE

120

15.2

Adjusting the play in the throttle cable x

- Move the handlebar to the straight-ahead position.

- Use the KTM diagnostics tool to set the motor drive to the basic position.

- Loosen counter nut .

- Set the play in the throttle cable by turning the adjusting screw .

Guideline

Throttle cable play

3… 5 mm (0.12… 0.2 in)

– Tighten counter nut .

600631-10

Adjusting the engine characteristic

15.3

- Switch off the ignition by turning the ignition key to position OFF

– Remove the seat. ( p. 63)

- Pull the Map-Select switch and holder  upward off of the retaining bracket.

- Pull the Map-Select switch out of the holder.

600641-10

TUNING THE ENGINE

121

- Turn the adjusting wheel until the desired digit is next to marking .

Set the Map-Select switch to Soft.

- Set the adjusting wheel to position 1.

Soft - reduced homologated peak performance for better driveability.

Set the Map-Select switch to Advanced.

- Set the adjusting wheel to position 2.

Advanced - homologated performance with extremely direct responsiveness.

Set the Map-Select switch to Standard.

100238-10

- Set the adjusting wheel to position 3, 4, 5, 6, 7, 8 or 9.

Standard - homologated performance with balanced responsiveness.

Set the Map-Select switch to poor fuel quality.

- Set the adjusting wheel to position 0.

Poor fuel quality - homologated performance is reduced in accordance with the

fuel quality, use for no more than 1 tank of fuel

- Position the Map-Select switch in the holder.

- Slide the Map-Select switch with the holder downward onto the retaining bracket.

- Mount the seat. ( p. 64)

SERVICE WORK ON THE ENGINE

122

Checking the engine oil level

16.1

Info

The engine oil level must be checked when the engine is warm.

Condition

The engine is at operating temperature.

- Stand the motorcycle upright on a horizontal surface.

- Check the engine oil level.

Info

After switching off the engine, wait one minute before checking the level.

The engine oil must be between the lower and upper edge of the oil level viewer.

» If the engine oil level is not at the specified level:

- Add the engine oil. ( p. 129)

600602-01

SERVICE WORK ON THE ENGINE

123

16.2

Changing the engine oil and filter, cleaning the oil screens x

- Drain the engine oil. x ( p. 123)

- Remove the oil filter. x ( p. 124)

- Clean the oil screens. x ( p. 126)

- Install the oil filter. x ( p. 128)

- Fill up with engine oil. x ( p. 128)

601022-10

Draining the engine oil x

16.3

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 regulations.

Info

Drain the engine oil only when the engine is warm.

SERVICE WORK ON THE ENGINE

124

- Place a suitable container under the engine.

- Remove the oil drain plug  with the magnet and seal ring.

- Completely drain the engine oil.

100200-10

- Thoroughly clean the oil drain plug with a magnet.

- Mount the oil drain plug with the magnet and seal ring and tighten it.

Guideline

Oil drain plug with magnet

M12x1.5

20 Nm

(14.8 lbf ft)

100201-01

Removing the oil filter x

16.4

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.

SERVICE WORK ON THE ENGINE

125

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.

- Place a suitable container under the engine.

- Remove screws . Remove the oil filter cover  with the O-ring.

- Pull oil filter  out of the oil filter housing.

Circlip pliers reverse (51012011000)

100202-10

- Remove screws . Remove oil filter  with the O-ring.

- Pull oil filter  out of the oil filter housing.

Circlip pliers reverse (51012011000)

- Completely drain the engine oil.

- Thoroughly clean the parts and sealing area.

100203-10

SERVICE WORK ON THE ENGINE

126

Cleaning the oil screens x

16.5

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 regulations.

- Place a suitable container under the engine.

- Remove plug  with oil screen  and the O-rings.

100205-10

SERVICE WORK ON THE ENGINE

127

- Remove plug  with oil screen  and the O-rings.

- Completely drain the remaining engine oil.

- Thoroughly clean the parts and sealing area.

100206-10

- Position oil screen  with the O-rings.

- Mount and tighten screw plug  with the O-ring.

Guideline

Plug, oil screen

M20x1.5

15 Nm

(11.1 lbf ft)

100207-10

- Position oil screen  with the O-rings.

- Mount and tighten screw plug  with the O-ring.

Guideline

Plug, oil screen

M20x1.5

15 Nm

(11.1 lbf ft)

100208-10

SERVICE WORK ON THE ENGINE

128

16.6

Installing the oil filter x

- Insert oil filters  and .

- Oil the O-rings of the oil filter covers. Mount oil filter covers  and .

- Mount and tighten the screws.

Guideline

Screw, oil filter cover

6 Nm (4.4 lbf ft)

100204-10

Filling up with engine oil x

16.7

Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

- Remove filler plug with O-ring  from the clutch cover and add engine oil.

Engine oil

1.70 l (1.8 qt.)

Engine oil (SAE 10W/60)

(00062010035)

(

p. 159)

Alternative engine

Engine oil

oil

(SAE 10W/50)

(

p. 159)

– Refit plug with O-ring  and tighten it.

100209-10

SERVICE WORK ON THE ENGINE

129

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 check that it is oil-tight.

- Check the engine oil level. ( p. 122)

Adding engine oil

16.8

Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

- Remove the oil filler plug with O-ring  from the clutch cover and fill up with engine

oil.

Engine oil (SAE 10W/60) (00062010035) ( p. 159)

Engine oil (SAE 10W/50) ( p. 159)

Info

For optimal performance of the engine oil, do not mix different types of engine

oil.

If appropriate, change the engine oil.

100209-10

- Install and tighten the oil filler plug with O-ring .

SERVICE WORK ON THE ENGINE

130

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 check that it is oil-tight.

- Check the engine oil level. ( p. 122)

CLEANING, CARE

131

Cleaning the motorcycle

17.1

Note

Material damage Damage and destruction of components by high-pressure cleaning equipment.

- Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical

components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts.

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

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.

- Seal the exhaust system to keep water out.

- First remove coarse dirt particles with a gentle spray of water.

- Spray very dirty areas with a normal motorcycle cleaner and then clean with a brush.

Motorcycle cleaner ( p. 163)

Info

Clean the vehicle using a soft sponge and warm water containing normal motor-

cycle cleaner.

401061-01

If the vehicle was operated in road salt, clean it with cold water. Warm water

enhances the corrosive effects of salt.

- After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly.

CLEANING, CARE

132

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.

After cleaning, ride the vehicle a short distance until the engine is warm, applying the

brakes occasionally.

Info

The heat produced causes water at inaccessible locations in the engine and the

brakes to evaporate.

Push back the protection covers 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. 66)

–

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. 162)

Treat all painted parts with a mild paint polish.

High-luster polish for paint ( p. 162)

Treat all plastic parts and powder-coated parts with a mild cleaning and care agent.

Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic

surfaces ( p. 163)

Oil the ignition/steering lock.

Universal oil spray ( p. 163)

CLEANING, CARE

133

Protective treatment for winter operation

17.2

Info

If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive

road salt.

If the vehicle was operated in road salt, clean it with cold water. Warm water enhances the corrosive effects of salt.

- Clean the motorcycle. ( p. 131)

- 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 use on salted roads, clean the motorcycle thoroughly with cold water and

dry it properly.

401060-01

- Clean the chain. ( p. 66)

STORAGE

134

Storage

18.1

Info

If you want to garage the motorcycle for a longer period, take the following actions.

Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should

do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the

new season.

Make sure the tank is as empty as possible so that you can fill up with fresh fuel when

you put the motorcycle back into operation.

Clean the motorcycle. ( p. 131)

–

Change the engine oil and filter, clean the oil screens. x

(

p. 123)

–

Check the antifreeze and coolant level. ( p. 112)

–

Check the tire air pressure. ( p. 95)

–

Remove the battery. x

(

p. 98)

–

Recharge the battery. x

(

p. 99)

401058-01

Guideline

Storage temperature of battery without

0… 35 °C (32… 95 °F)

direct sunshine

Store the vehicle in a dry location that is not subject to large fluctuations in tempera-

ture.

Info

KTM recommends jacking up the motorcycle.

Raise the motorcycle with the rear wheel stand. ( p. 62)

–

Raise the motorcycle with the front wheel stand. ( p. 61)

STORAGE

135

- Cover the motorcycle with a tarp or cover that is permeable to air.

Info

Do not use non-porous materials since they prevent humidity from escaping,

thus causing corrosion.

Avoid running the engine for a short time only. Since the engine cannot warm

up properly, the water vapor produced during combustion condenses and causes

valves and exhaust system to rust.

Preparing for use after storage

18.2

- Take the motorcycle off of the front wheel stand. ( p. 61)

- Take the motorcycle off of the rear wheel stand. ( p. 62)

- Recharge the battery. x

(

p. 99)

– Install the battery. x (

p. 99)

- Set the clock. ( p. 28)

- Refuel. ( p. 49)

- Perform checks and vehicle care when preparing for use. ( p. 41)

- Take a test ride.

401059-01

TROUBLESHOOTING

136

Faults

Possible cause

Action

The engine does not turn when the

Operating error

Carry out the start procedure. ( p. 42)

starter button is pressed

Battery is discharged

Recharge the battery. x

(

p. 99)

Fuse 1, 2, 3 or 4 is blown

Change the fuses of individual power consumers.

(

p. 103)

Main fuse burned out

Change the main fuse. ( p. 101)

No ground connection present.

Check the ground connection.

Engine turns only if the clutch lever is

The vehicle is in gear

Shift gear to neutral.

drawn

The vehicle is in gear and the side

Shift gear to neutral.

stand is folded out

Engine turns but does not start.

Operating error

Carry out the start procedure. ( p. 42)

Fuse 4 blown

Change the fuses of individual power consumers.

(

p. 103)

Coupling of fuel hose connection not

Reconnect coupling of fuel hose connection.

connected

Socket connector of wiring harness is

Clean the socket connector and treat it with con-

oxidized

tact spray.

Defect in fuel injection system

Read out the fault memory using the KTM diag-

nostics tool. x

Engine has too little power.

Air filter is very dirty

Remove the air filter. x ( p. 64)

–

Install the air filter. x ( p. 65)

Fuel filter is very dirty

Check the fuel pressure. x

Defect in fuel injection system

Read out the fault memory using the KTM diag-

nostics tool. x

Engine overheats.

Too little coolant in cooling system

Check the cooling system for leakage.

–

Check the coolant level. ( p. 114)

TROUBLESHOOTING

137

Faults

Possible cause

Action

Engine overheats.

Radiator fins very dirty

Clean radiator fins.

Foam formation in cooling system

Drain the coolant. x

(

p. 116)

–

Fill the cooling system. x

(

p. 117)

Buckled or damaged radiator hose

Change the radiator hose. x

Thermostat is faulty

Check the thermostat. x

Fuse 5 blown

Change the fuses of individual power consumers.

(

p. 103)

Defect in radiator fan system

Check the radiator fan system. x

Air in cooling system

Fill the cooling system. x ( p. 117)

FI warning lamp (MIL) lights/flashes

Defect in fuel injection system

Read out the fault memory using the KTM diag-

nostics tool. x

Engine dies during the journey

Lack of fuel

Refuel. ( p. 49)

Fuse 1, 2 or 4 blown

Change the fuses of individual power consumers.

(

p. 103)

High oil consumption

Engine vent hose bent

Route the vent hose without bends or change it if

necessary.

Engine oil level too high

Check the engine oil level. ( p. 122)

Engine oil too thin (low viscosity)

Change the engine oil and filter, clean the oil

screens. x

(

p. 123)

Headlight and parking light not func-

Fuse 7 blown

Change the fuses of individual power consumers.

tioning

(

p. 103)

Turn signal, brake light and horn not

Fuse 6 blown

Change the fuses of individual power consumers.

functioning

(

p. 103)

TROUBLESHOOTING

138

Faults

Possible cause

Action

Time is not (correctly) displayed

Fuse 2 blown

- Change the fuses of individual power consumers.

(

p. 103)

– Set the clock. ( p. 28)

Battery discharged

Ignition not switched off when vehicle

- Recharge the battery. x

(

p. 99)

was parked

Battery is not charged by alternator

- Check the charging voltage. x

- Check the quiescent current. x

Combination instrument shows nothing

Fuse 1 blown

- Change the fuses of individual power consumers.

in the display

(

p. 103)

Speedometer in combination instru-

Speedometer wiring harness is dam-

- Check the wiring harness and plug-in connection.

ment not functioning

aged or plug-in connection is oxidized

BLINK CODE

139

Blink code FI of warning lamp

(MIL)

02 FI warning lamp (MIL) flashes briefly 2x

Error level condition

Crankshaft position sensor - circuit fault

Blink code FI of warning lamp

(MIL)

06 FI warning lamp (MIL) flashes briefly 6x

Error level condition

Throttle position sensor circuit A - input signal too low

Throttle position sensor circuit A - input signal too high

Blink code FI of warning lamp

(MIL)

08 FI warning lamp (MIL) flashes briefly 8x

Error level condition

Accelerator position sensor - input signal too low

Accelerator position sensor - input signal too high

Blink code FI of warning lamp

(MIL)

09 FI warning lamp (MIL) flashes briefly 9x

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 FI of warning lamp

(MIL)

12 FI warning lamp (MIL) flashes 1x long, 2x short

Error level condition

Engine coolant temperature sensor - input signal too low

Engine coolant temperature sensor - input signal too high

BLINK CODE

140

Blink code FI of warning lamp

(MIL)

13 FI warning lamp (MIL) flashes 1x long, 3x short

Error level condition

Intake air temperature sensor - input signal too low

Intake air temperature sensor - input signal too high

Blink code FI of warning lamp

(MIL)

14 FI warning lamp (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 FI warning lamp (MIL) flashes 1x long, 5x short

Error level condition

Rollover sensor - input signal too low

Rollover sensor - input signal too high

Blink code FI of warning lamp

(MIL)

17 FI warning lamp (MIL) flashes 1x long, 7x short

Error level condition

Lambda sensor cylinder 1, sensor 1 - circuit fault

Blink code FI of warning lamp

(MIL)

24 FI warning lamp (MIL) flashes 2x long, 4x short

Error level condition

System voltage - circuit fault

BLINK CODE

141

Blink code FI of warning lamp

(MIL)

25 FI warning lamp (MIL) flashes 2x long, 5x short

Error level condition

Side stand switch - circuit fault

Blink code FI of warning lamp

(MIL)

26 FI warning lamp (MIL) flashes 2x long, 6x short

Error level condition

Motor drive hall sensor - circuit fault

Blink code FI of warning lamp

(MIL)

37 FI warning lamp (MIL) flashes 3x long, 7x short

Error level condition

Ignition coil 1, cylinder 1 - circuit fault

Blink code FI of warning lamp

(MIL)

41 FI warning lamp (MIL) flashes 4x long, 1x short

Error level condition

Fuel pump controller - short circuit to ground or open circuit

Fuel pump controller - input signal too high

Blink code FI of warning lamp

(MIL)

45 FI warning lamp (MIL) flashes 4x long, 5x short

Error level condition

Lambda sensor heater cylinder 1, sensor 1 - short circuit to ground or open circuit

Lambda sensor heater cylinder 1, sensor 1 - input signal too high

BLINK CODE

142

Blink code FI of warning lamp

(MIL)

54 FI warning lamp (MIL) flashes 5x long, 4x short

Error level condition

Secondary air valve - short circuit to ground or open circuit

Blink code FI of warning lamp

(MIL)

58 FI warning lamp (MIL) flashes 5x long, 8x short

Error level condition

EPT motor drive relay permission - signal fault

Blink code FI of warning lamp

(MIL)

60 FI warning lamp (MIL) flashes 6x long

Error level condition

Motor drive - circuit fault

Blink code FI of warning lamp

(MIL)

90 FI warning lamp (MIL) flashes 9x long

Error level condition

Throttle position - circuit fault

Blink code FI of warning lamp

(MIL)

91 FI warning lamp (MIL) flashes 9x long, 1x short

Error level condition

CAN bus communication error

TECHNICAL DATA - ENGINE

144

Design

1-cylinder 4-stroke engine, water-cooled

Displacement

654 cm³ (39.91 cu in)

Stroke

80 mm (3.15 in)

Bore

102 mm (4.02 in)

Compression ratio

11.8:1

Idle speed

Coolant temperature: ≥

°C (≥

158

°F)

1,550… 1,650 rpm

Control

OHC, 4 valves controlled via rocker arm, chain drive

Valve diameter, intake

40 mm (1.57 in)

Valve diameter, exhaust

34 mm (1.34 in)

Valve play, cold

0.07… 0.13 mm (0.0028… 0.0051 in)

Crankshaft bearing

2 roller bearings

Conrod bearing

Needle bearing

Piston pin bearing

Bronze bush

Pistons

Forged light alloy

Piston rings

1 L-ring, 1 tapered compression piston ring, 1 oil scraper ring

Engine lubrication

Semi-dry sump lubrication with two rotor pumps

Primary transmission

36:79

Clutch

APTC™ Antihopping clutch in oil bath / hydraulically operated

Gearbox

6-gears, claw-shifted

Transmission ratio

1st gear

14:35

2nd gear

16:28

3rd gear

21:28

4th gear

21:23

TECHNICAL DATA - ENGINE

145

5th gear

23:22

6th gear

23:20

Mixture preparation

Electronic fuel injection

Ignition

Contactless controlled fully electronic ignition with digital ignition

adjustment

Alternator

12 V, 224 W

Spark plug

NGK LKAR 8AI - 9

Spark plug electrode gap

0.9 mm (0.035 in)

Cooling

Water cooling, permanent circulation of coolant by water pump

Starting aid

Electric starter, automatic decompressor

21.1

Capacity - engine oil

Engine oil

1.70 l (1.8 qt.)

Engine oil (SAE 10W/60) (00062010035) ( p. 159)

Alternative engine oil

Engine oil (SAE 10W/50)

(

p. 159)

Capacity - coolant

21.2

Coolant

1.20 l (1.27 qt.)

Coolant ( p. 158)

Coolant (mixed ready to use) ( p. 158)

TECHNICAL DATA - ENGINE TIGHTENING TORQUES

146

Oil hole plug

self-tapping

9 Nm (6.6 lbf ft)

Loctite^®

243™

Screw, membrane fixation

2.5 Nm (1.84 lbf ft)

Loctite^®

243™

Hose clamp, intake flange

1.5 Nm (1.11 lbf ft)

Oil jet, conrod lubrication

2 Nm (1.5 lbf ft)

Loctite^®

243™

Locking screw for bearing

6 Nm (4.4 lbf ft)

Loctite^®

243™

Screw, breather cover on valve cover

3 Nm (2.2 lbf ft)

Loctite^®

243™

Screw, clutch spring

6 Nm (4.4 lbf ft)

Screw, cover plate for oil return line

6 Nm (4.4 lbf ft)

Screw, gear sensor

5 Nm (3.7 lbf ft)

Loctite^®

243™

Screw, oil filter cover

6 Nm (4.4 lbf ft)

Screw, oil pump cover

6 Nm (4.4 lbf ft)

Loctite^®

243™

Plug, vacuum connection

10 Nm (7.4 lbf ft)

Loctite^®

243™

Screw in alternator cover

10 Nm (7.4 lbf ft)

Screw, alternator cover (chain shaft

10 Nm (7.4 lbf ft)

Loctite^®

243™

through-hole)

Screw, autodecompression

3… 4 Nm (2.2… 3

lbf ft)

Loctite^®

243™

Screw, axial lock of camshaft

10 Nm (7.4 lbf ft)

Loctite^®

243™

Screw, clutch cover

10 Nm (7.4 lbf ft)

Screw, clutch slave cylinder

M6x20

10 Nm (7.4 lbf ft)

Loctite^®

243™

Screw, clutch slave cylinder

M6x35

10 Nm (7.4 lbf ft)

Screw, cylinder

10 Nm (7.4 lbf ft)

Loctite^®

243™

Screw, cylinder head

10 Nm (7.4 lbf ft)

Loctite^®

243™

Screw, engine case

10 Nm (7.4 lbf ft)

Screw, ignition pulse generator

10 Nm (7.4 lbf ft)

Loctite^®

243™

TECHNICAL DATA - ENGINE TIGHTENING TORQUES

147

Screw, locking lever

10 Nm (7.4 lbf ft)

Loctite^®

243™

Screw, rocker arm shaft

12 Nm (8.9 lbf ft)

Screw, shift drum locating

10 Nm (7.4 lbf ft)

Loctite^®

243™

Screw, shift lever

10 Nm (7.4 lbf ft)

Loctite^®

222

Screw, starter motor

10 Nm (7.4 lbf ft)

Loctite^®

243™

Screw, stator bracket

10 Nm (7.4 lbf ft)

Loctite^®

243™

Screw, thermostat housing

10 Nm (7.4 lbf ft)

Loctite^®

243™

Screw, timing chain guide rail

10 Nm (7.4 lbf ft)

Loctite^®

243™

Screw, timing chain tensioning rail

10 Nm (7.4 lbf ft)

Loctite^®

243™

Screw, valve cover

10 Nm (7.4 lbf ft)

Screw, water pump cover

10 Nm (7.4 lbf ft)

Screw, water pump wheel

10 Nm (7.4 lbf ft)

Loctite^®

243™

Oil jet, piston cooling

M6x0.75

4 Nm (3 lbf ft)

Loctite^®

243™

Plug, crankshaft location

20 Nm (14.8 lbf ft)

Stud, exhaust flange

10 Nm (7.4 lbf ft)

Loctite^®

243™

Cylinder head screw

M10

Tightening sequence:

Lubricated with engine oil

Tighten diagonally, beginning

with the rear screw on the

chain shaft.

Step 1

15 Nm (11.1 lbf ft)

Step 2

30 Nm (22.1 lbf ft)

Step 3

45 Nm (33.2 lbf ft)

Step 4

60 Nm (44.3 lbf ft)

TECHNICAL DATA - ENGINE TIGHTENING TORQUES

148

Oil hole plug

M10x1

15 Nm (11.1 lbf ft)

Loctite^®

243™

Plug, drain hole of water pump

M10x1

15 Nm (11.1 lbf ft)

Plug, oil bore for oil radiator

M10x1

15 Nm (11.1 lbf ft)

Screw, unlocking of timing chain ten-

M10x1

10 Nm (7.4 lbf ft)

sioner

Spark plug

M12x1.25

17 Nm (12.5 lbf ft)

Coolant temperature sensor on cylinder

M12x1.5

12 Nm (8.9 lbf ft)

head

Oil drain plug with magnet

M12x1.5

20 Nm (14.8 lbf ft)

Oil pressure regulator valve plug

M12x1.5

20 Nm (14.8 lbf ft)

Plug, oil bore

M14x1.5

15 Nm (11.1 lbf ft)

Loctite^®

243™

Engine case stud

M16x1.5

25 Nm (18.4 lbf ft)

Loctite^®

243™

Rotor nut

M18x1.5

100 Nm (73.8 lbf ft)

Nut, engine sprocket

M20x1.5

60 Nm (44.3 lbf ft)

Loctite^®

243™

Nut, inner clutch hub

M20x1.5

100 Nm (73.8 lbf ft)

Loctite^®

243™

Nut, primary gear

M20LHx1.5

90 Nm (66.4 lbf ft)

Loctite^®

243™

Plug, oil screen

M20x1.5

15 Nm (11.1 lbf ft)

Plug, timing chain tensioner

M20x1.5

25 Nm (18.4 lbf ft)

Plug, oil thermostat

M24x1.5

15 Nm (11.1 lbf ft)

Screw in alternator cover

M24x1.5

8 Nm (5.9 lbf ft)

TECHNICAL DATA - CHASSIS

149

Frame

Lattice frame made of chrome molybdenum steel tubing, powder-

coated

Fork

WP Suspension Up Side Down 4860 ROMA

Shock absorber

WP Suspension 4618 with Pro-Lever deflector

Suspension travel

Front

275 mm (10.83 in)

Rear

265 mm (10.43 in)

Brake system

Front

Disc brake with radially screwed four-piston brake caliper, floating

brake disc

Rear

Disc brake with single-piston brake caliper, floating

Brake discs - diameter

Front

320 mm (12.6 in)

Rear

240 mm (9.45 in)

Brake discs - wear limit

Front

4.0 mm (0.157 in)

Rear

4.5 mm (0.177 in)

Tire air pressure, solo

Front

2.0 bar (29 psi)

Rear

2.0 bar (29 psi)

Tire air pressure with passenger / fully loaded

Front

2.0 bar (29 psi)

Rear

2.2 bar (32 psi)

Secondary drive ratio

16:42

Chain

5/8 x 1/4” X-ring

TECHNICAL DATA - CHASSIS

150

Steering head angle

63°

Wheelbase

1,480±15 mm (58.27±0.59 in)

Seat height unloaded

910 mm (35.83 in)

Ground clearance unloaded

290 mm (11.42 in)

Weight without fuel approx.

139.5 kg (307.5 lb.)

Maximum permissible front axle load

150 kg (331 lb.)

Maximum permissible rear axle load

200 kg (441 lb.)

Maximum permissible overall weight

350 kg (772 lb.)

Battery

YTZ10S

Battery voltage: 12 V

Nominal capacity: 8.6 Ah

maintenance-free

Fuse

58011109130

30 A

Fuse

75011088015

15 A

Fuse

75011088010

10 A

Lighting equipment

23.1

Headlight

H4 / socket P43t

12 V

60/55 W

Parking light

W5W / socket W2.1x9.5d

12 V

Instrument lights and indicator lamps

LED

Turn signal

RY10W / socket BAU15s

12 V

10 W

Brake/tail light

LED

TECHNICAL DATA - CHASSIS

151

License plate lamp

W5W / socket W2.1x9.5d

12 V

23.2

Tires

Front tire

Rear tire

120/70 ZR 17 M/C 58W TL

160/60 ZR 17 M/C 69W TL

Pirelli Dragon Supercorsa Pro

Additional information is available in the Service section under:

http://www.ktm.com

23.3

Capacity - fuel

Total fuel tank capacity, approx.

12 l (3.2 US gal)

Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. 161)

Fuel reserve, approx.

2.5 l (2.6 qt.)

TECHNICAL DATA - FORK

152

Fork part number

14.18.7K.12

Fork

WP Suspension Up Side Down

4860

ROMA

Compression damping

Comfort

20 clicks

Standard

15 clicks

Sport

10 clicks

Full payload

10 clicks

Rebound damping

Comfort

15 clicks

Standard

10 clicks

Sport

5 clicks

Full payload

5 clicks

Spring length with preload spacer(s)

480 mm (18.9 in)

Spring rate

Soft

5.0 N/mm (28.6 lb/in)

Medium (standard)

5.2 N/mm (29.7 lb/in)

Hard

5.4 N/mm (30.8 lb/in)

Air chamber length

100±20 mm (3.94±0.79 in)

Fork length

915 mm (36.02 in)

Fork oil per fork leg

634

ml (21.44

fl. oz.)

Fork oil (SAE 5) ( p. 160)

TECHNICAL DATA - SHOCK ABSORBER

153

Shock absorber part number

15.18.7E.12

Shock absorber

WP Suspension

4618

with Pro-Lever deflector

Compression damping, high-speed

Comfort

1.5 turns

Standard

1 turn

Sport

0.5 turn

Full payload

0.5 turn

Compression damping, low-speed

Comfort

20 clicks

Standard

15 clicks

Sport

10 clicks

Full payload

10 clicks

Rebound damping

Comfort

20 clicks

Standard

15 clicks

Sport

10 clicks

Full payload

10 clicks

Spring preload

18 mm (0.71

in)

Spring rate

Soft

80 N/mm (457 lb/in)

Medium (standard)

85 N/mm (485 lb/in)

Hard

90 N/mm (514 lb/in)

Spring length

220 mm (8.66 in)

Gas pressure

10 bar (145 psi)

Static sag

20 mm (0.79 in)

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES

155

Screw, license plate holder, bottom

EJOT

3 Nm (2.2 lbf ft)

Screw, side stand switch

EJOT

2 Nm (1.5 lbf ft)

Screw, SLS valve

EJOT

2 Nm (1.5 lbf ft)

Spoke nipple, front wheel

M4.5

4 Nm (3 lbf ft)

Bolt, foot brake lever stub

6 Nm (4.4 lbf ft)

Loctite^®

243™

Remaining screws, chassis

5 Nm (3.7 lbf ft)

Screw, electrical holder

3 Nm (2.2 lbf ft)

Screw, exhaust heat shield

6 Nm (4.4 lbf ft)

Loctite^®

243™

Screw, fuel level sensor

3 Nm (2.2 lbf ft)

Screw, fuel pump

6 Nm (4.4 lbf ft)

Screw, headlight mask

5 Nm (3.7 lbf ft)

Screw, starter cable on starter

3 Nm (2.2 lbf ft)

Spoke nipple, rear wheel

4 Nm (3 lbf ft)

Nut, foot brake cylinder screw

10 Nm (7.4 lbf ft)

Remaining nuts, chassis

15 Nm (11.1 lbf ft)

Remaining screws on fuel tank

5 Nm (3.7 lbf ft)

Remaining screws, chassis

10 Nm (7.4 lbf ft)

Screw, air filter box top

2 Nm (1.5 lbf ft)

Screw, ball joint of push rod on foot

10 Nm (7.4 lbf ft)

Loctite^®

243™

brake cylinder

Screw, brake fluid reservoir of rear brake

5 Nm (3.7 lbf ft)

Screw, chain sliding guard

6 Nm (4.4 lbf ft)

Loctite^®

243™

Screw, front brake disc

14 Nm (10.3 lbf ft)

Loctite^®

243™

Screw, ignition lock

10 Nm (7.4 lbf ft)

Loctite^®

243™

Screw, lower radiator bracket

8 Nm (5.9 lbf ft)

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES

156

Screw, magnetic holder on side stand

12 Nm (8.9 lbf ft)

Loctite^® 243™

Screw, rear brake disc

14 Nm (10.3 lbf ft)

Loctite^® 243™

Screw, seat lock

5 Nm (3.7 lbf ft)

Loctite^® 222

Screw, side cover

5 Nm (3.7 lbf ft)

Screw, upper radiator bracket

12 Nm (8.9 lbf ft)

Screw, voltage regulator

8 Nm (5.9 lbf ft)

Nut, manifold on cylinder head

Nm (18.4 lbf ft)

Copper paste

Nut, rear sprocket screw

Nm (25.8 lbf ft)

Loctite^®

243™

Remaining nuts, chassis

Nm (22.1 lbf ft)

Remaining screws, chassis

Nm (18.4 lbf ft)

Screw, bottom triple clamp

Nm (8.9 lbf ft)

Screw, chain sliding piece

Nm (11.1 lbf ft)

Screw, connection lever on frame

Nm (22.1 lbf ft)

Loctite^®

243™

Screw, exhaust clamp on main silencer

Nm (18.4 lbf ft)

Screw, foot brake lever

Nm (20.7 lbf ft)

Loctite^®

243™

Screw, fork stub

Nm (11.1 lbf ft)

Screw, front footrest bracket

Nm (18.4 lbf ft)

Screw, fuel tank, bottom

Nm (20.7 lbf ft)

Loctite^®

243™

Screw, fuel tank, top

Nm (20.7 lbf ft)

Loctite^®

243™

Screw, handlebar clamp

Nm (14.8 lbf ft)

Screw, handrail

Nm (14.8 lbf ft)

Screw, license plate holder, top

Nm (14.8 lbf ft)

Screw, main silencer holder

Nm (18.4 lbf ft)

Screw, main silencer holder on fuel tank

Nm (18.4 lbf ft)

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES

157

Screw, rear footrest bracket

M8x16

Nm (18.4 lbf ft)

Screw, side stand bracket

Nm (20.7 lbf ft)

Loctite^®

243™

Screw, spring holder on side stand

Nm (18.4 lbf ft)

Loctite^®

243™

bracket

Screw, steering stem

Nm (14.8 lbf ft)

Loctite^®

243™

Screw, top triple clamp

Nm (12.5 lbf ft)

Engine carrying screw

M10

Nm (33.2 lbf ft)

Loctite^®

243™

Remaining nuts, chassis

M10

Nm (36.9 lbf ft)

Remaining screws, chassis

M10

Nm (33.2 lbf ft)

Screw, bottom shock absorber

M10

Nm (33.2 lbf ft)

Loctite^®

243™

Screw, engine bearer on frame

M10

Nm (33.2 lbf ft)

Screw, handlebar support

M10

Nm (29.5 lbf ft)

Screw, side stand

M10

Nm (25.8 lbf ft)

Loctite^®

243™

Screw, top shock absorber

M10

Nm (33.2 lbf ft)

Loctite^®

243™

Screw, front brake caliper

M10x1.25

Nm (33.2 lbf ft)

Loctite^®

243™

Screw, swingarm pivot

M12

Nm (59 lbf ft)

Lambda sensor

M12x1.25

Nm (18.4 lbf ft)

Copper paste

Nut, linkage lever on swingarm

M14x1.5

100 Nm (73.8 lbf ft)

Nut, linkage lever to rocker arm

M14x1.5

100 Nm (73.8 lbf ft)

Screw, bottom steering head

M20x1.5

60 Nm (44.3 lbf ft)

Loctite^® 243™

Screw, top steering head

M20x1.5

12 Nm (8.9 lbf ft)

Screw, front wheel spindle

M24x1.5

40 Nm (29.5 lbf ft)

Nut, rear wheel spindle

M25x1.5

90 Nm (66.4 lbf ft)

SUBSTANCES

158

Brake fluid DOT 4 / DOT 5.1

According to

- DOT

Guideline

- Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the correspond-

ing properties. KTM recommends Castrol and Motorex^® 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…

50 % corrosion inhibitor/antifreeze

−49 °F)

50 % distilled water

Coolant (mixed ready to use)

Antifreeze

−40 °C (−40 °F)

Supplier

Motorex^®

- Anti Freeze

SUBSTANCES

159

Engine oil (SAE 10W/60) (00062010035)

According to

- JASO T903 MA ( p. 164)

- SAE ( p. 164) (SAE 10W/60)

- KTM LC4 2007+

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

Supplier

Motorex^®

- Motorex^® KTM Cross Power 4T

Engine oil (SAE 10W/50)

According to

- JASO T903 MA ( p. 164)

- SAE ( p. 164) (SAE 10W/50)

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.

Fully synthetic engine oil

Supplier

Motorex^®

- Power Synt 4T

SUBSTANCES

160

Fork oil (SAE 5)

According to

- SAE ( p. 164) (SAE 5)

Guideline

- Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding proper-

ties. KTM recommends Motorex^® products.

Supplier

Motorex^®

- Racing Fork Oil

Hydraulic 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. 164) (SAE 2,5)

Guideline

- Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding proper-

ties.

AUXILIARY SUBSTANCES

162

Chain cleaner

Guideline

- KTM recommends Motorex^® products.

Supplier

Motorex^®

- Chain Clean

Chain 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

High-luster polish for paint

Guideline

- KTM recommends Motorex^® products.

Supplier

Motorex^®

- Moto Polish

AUXILIARY SUBSTANCES

163

Long-life 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

Universal oil spray

Guideline

- KTM recommends Motorex^® products.

Supplier

Motorex^®

- Joker 440 Synthetic

STANDARDS

164

JASO T903 MA

Different technical development directions required a new specification for 4-stroke motorcycles - the JASO T903 MA Standard. Ear-

lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification.

Whereas long service 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 according to their viscos-

ity. The viscosity describes only one property of oil and says nothing about quality.

INDEX

165

INDEX

Braking

Accessories

Air filter

Chain

installing

checking

removing

cleaning

Antifreeze

dirt, checking for

checking

112

Chain guide

checking

Baggage

Chain tension

adjusting

Battery

checking

fitting

recharging

. . . . . . 99

Changing turn signal bulb

109

removing

Chassis number

Blink code

139-143

Clutch

checking/correcting fluid level

Brake discs

checking

Clutch lever

basic position, adjusting

Brake fluid

front brake, adding

. . . . . . 79

Combination instrument

rear brake, adding

. . . . . . 83

clock, setting

coolant temperature indicator

Brake fluid level

display

front brake, checking

function buttons

rear brake, checking

. . . . . . 83

indicator lamps

Brake linings

kilometers or miles, setting

front brake, checking

ODO display

rear brake, checking

. . . . . . 85

speed display

Brakes

tachometer

INDEX

166

time

Engine oil level

TRIP 1 display, setting/resetting

checking

122

TRIP 2 display, setting/resetting

Engine sprocket

TRIP F display

checking

Coolant

Environment

draining

116

Coolant level

Filler cap

checking

112,

114

closing

Cooling system

112

opening

filling

117

Filling up

fuel

Display

Foot brake lever

basic position, adjusting

Electric starter button

free travel, checking

Emergency OFF switch

Fork

Engine

adjusting compression damping

running in

adjusting rebound

fork legs, bleeding

Engine characteristic

adjusting

120

Fork part number

Engine number

Front wheel

fitting

Engine oil

removing

adding

129

changing

123

Fuel, oils, etc

draining

123

Fuse

refilling

128

of individual power consumer, changing

103

INDEX

167

Motorcycle

cleaning

131

Hand brake lever

raising with the front wheel stand

. 61

basic position, adjusting

. 77

raising with the rear wheel stand

Handrails

taking off of the front wheel stand

. 61

Headlight

taking off of the rear wheel stand

. 62

light range, adjusting

111

Headlight adjustment

Oil filter

low beam, checking

110

changing

123

Headlight bulb, changing

107

installing

128

Headlight mask with headlight

removing

124

installing

106

Oil screen

removing

105

cleaning

126

Horn button

Oil screens

cleaning

123

Ignition lock

Owner's manual

Indicator lamps

Parking

Key number

Parking light bulb

changing

108

Light switch

Passenger footrests

. 34

Loading the vehicle

Play in throttle cable

adjusting

120

checking

119

Main fuse

Preparing for use

changing

101

checks and vehicle care when preparing for use

INDEX

168

Protective treatment for winter operation

133

compression damping, high-speed, adjusting

. 58

compression damping, low-speed, adjusting

Putting into operation

advice on first use

Shock absorber part number

. 18

after storage

135

Side stand

Spare parts

Spoke tension

Rear hub rubber dampers

checking

Starting

Rear sprocket

Steering lock

checking

Stopping

Rear wheel

Storage

134

fitting

removing

Tachometer

Riding

starting off

Technical data

chassis

149-151

chassis tightening torques

155-157

Seat

engine

144-145

mounting

engine tightening torques

146-148

removing

fork

152

Seat release

shock absorber

153-154

Service

Throttle grip

Service plan

52-54

Tire air pressure

Shift lever

checking

Shifting

Tire condition

Shock absorber

checking

adjusting rebound damping

Transport

compression damping, general