KTM 1090 Adventure R Owner'S Manual Download

Page: 134 / 307

13 SERVICE WORK ON THE CHASSIS

132

D03116-10

–

Secure the motorcycle against falling over.

–

Remove special tool

Work stand (62529055100)

Info

To avoid damaging components, lower the motorcycle
slowly from the work stand.
The assistance of a second person can be useful.

–

Lean the motorcycle on the side stand.

–

Remove the fixing means on the rider footrests.

Summary of Contents for 1090 Adventure R

Page 1: ...OWNER S MANUAL 2018 1090 Adventure R Art no 3213756en...

Page 2: ......

Page 3: ...ver minor differences due to further developments in design cannot be ruled out completely All specifications are non binding KTM Sportmotorcycle GmbH specifically reserves the right to modify or dele...

Page 4: ...61 According to the international quality management standard ISO 9001 KTM uses quality assur ance processes that lead to the maximum possible quality of the products Issued by T V Management Service...

Page 5: ...18 3 3 Spare parts accessories 18 3 4 Service 19 3 5 Figures 19 3 6 Customer service 19 4 VIEW OF VEHICLE 22 4 1 View of vehicle front left example 22 4 2 View of vehicle rear right example 24 5 SERIA...

Page 6: ...lever 48 6 21 Foot brake lever 49 6 22 Side stand 50 7 COMBINATION INSTRUMENT 51 7 1 Overview 51 7 2 Activation and test 51 7 3 Matrix display 53 7 4 Segment display 53 7 5 Fuel level display 54 7 6...

Page 7: ...ING FOR USE 89 9 1 Advice on preparing for first use 89 9 2 Running in the engine 91 9 3 Loading the vehicle 91 10 RIDING INSTRUCTIONS 94 10 1 Checks and maintenance measures when preparing for use 94...

Page 8: ...6 Removing the motorcycle from the work stand inserted 131 13 7 Removing the seat 133 13 8 Mounting the seat 133 13 9 Checking for chain dirt 134 13 10 Cleaning the chain 134 13 11 Checking the chain...

Page 9: ...wheel 192 15 4 Installing the rear wheel 195 15 5 Checking the rear hub rubber dampers 198 15 6 Checking the tire condition 200 15 7 Checking the tire air pressure 202 15 8 Checking spoke tension 203...

Page 10: ...ANING CARE 258 20 1 Cleaning motorcycle 258 20 2 Checks and maintenance steps for winter operation 261 21 STORAGE 263 21 1 Storage 263 21 2 Preparing for use after storage 264 22 TROUBLESHOOTING 265 2...

Page 11: ...TABLE OF CONTENTS 9 29 2 Yellow and orange symbols 296 29 3 Green and blue symbols 297 INDEX 298...

Page 12: ...ith this symbol requires specialist knowledge and technical understanding In the interest of your own safety have these jobs performed by an authorized KTM workshop Your motorcycle will be optimally c...

Page 13: ...rework 1 2 Formats used The typographical formats used in this document are explained below Proprietary name Indicates a proprietary name Name Indicates a protected name Brand Indicates a brand availa...

Page 14: ...Dangers can arise for people property and the environment through use not as intended Any use of the vehicle beyond the intended and defined use constitutes misuse Misuse also includes the use of ope...

Page 15: ...variably lead to fatal or serious permanent injury if the appropriate measures are not taken Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures ar...

Page 16: ...ed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below 1 Removal or puncturing of the main silencer baffles header pipes or any other comp...

Page 17: ...ch as the exhaust system radiator engine shock absorber or brake system before the vehicle parts have cooled down Let the vehicle parts cool down before you perform any work on the vehicle Only operat...

Page 18: ...2 8 Work rules Special tools are necessary for some of the work These are not included with the vehicle and can be ordered under the number in parentheses Ex valve spring mounter 59029019000 During as...

Page 19: ...advise you 2 10 Owner s Manual It is important that you read this Owner s Manual carefully and completely before making your first trip The Own er s Manual contains useful information and many tips o...

Page 20: ...3 2 Operating and auxiliary substances Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system Us...

Page 21: ...of components such as the drive train brakes or air filter For this reasons it may be necessary to service or replace worn parts before the interval listed in the service schedule is reached It is im...

Page 22: ...3 IMPORTANT NOTES 20 A list of authorized KTM dealers can be found on the KTM website International KTM Website http www ktm com...

Page 23: ...3 IMPORTANT NOTES 21...

Page 24: ...4 VIEW OF VEHICLE 22 4 1 View of vehicle front left example A00220 10...

Page 25: ...23 1 Clutch lever p 30 2 Grab handles p 46 3 Luggage rack plate p 46 4 Passenger footrest p 48 5 Seat lock p 45 6 Rider footrests p 81 7 Shift lever p 48 8 Side stand p 50 9 Engine oil level viewer b...

Page 26: ...4 VIEW OF VEHICLE 24 4 2 View of vehicle rear right example A00218 10...

Page 27: ...adjustment 4 Electric starter button p 36 5 Emergency OFF switch p 36 6 Fork rebound adjustment 7 Hand brake lever p 30 8 Storage compartment 9 Cooling system compensating tank bk Foot brake lever p 4...

Page 28: ...The chassis number 1 is stamped on the bottom right of the frame behind the steering head The chassis number is also shown on the type label 5 2 Type label 402293 10 EU Type label 1 is affixed to the...

Page 29: ...0 The key number Code number 1 can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place Use the orange programming key to activate and dea...

Page 30: ...IAL NUMBERS 28 5 4 Engine number 402296 10 The engine number 1 is stamped on the right side of the engine 5 5 Fork part number 402295 10 The fork part number 1 is stamped on the inner side of the fork...

Page 31: ...SERIAL NUMBERS 5 29 5 6 Shock absorber article number 402339 10 The shock absorber article number 1 is stamped on the top of the shock absorber...

Page 32: ...1 is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 6 2 Hand brake lever S01749 10 The hand brake lever 1 is fitted on the right side of the handle b...

Page 33: ...tle grip S01749 11 The throttle grip 1 is fitted on the right side of the handlebar 6 4 Switches on the left side of the handlebar 6 4 1 Combination switch The combination switch is fitted on the left...

Page 34: ...6 4 2 Light switch M00548 10 The light switch 1 is fitted on the combination switch on the left Possible states Low beam on Light switch in position A In this position the low beam and tail light are...

Page 35: ...itua tions Info The hazard warning flasher can be activated or deactivated while the ignition is switched on or up to 60 seconds after the ignition is switched off Only keep the hazard warning flasher...

Page 36: ...is the BACK button 6 4 5 Turn signal switch S00217 10 Turn signal switch 1 is fitted on the combination switch on the left Possible states Turn signal off Push the turn signal switch toward the switc...

Page 37: ...least 10 seconds and 150 meters of riding distance the turn signal is switched off If the vehicle is stationary both counters are stopped If the turn signal switch is reactivated both counters are re...

Page 38: ...ted a running engine stops and a non running engine cannot be started A message appears on the matrix display Emergency OFF switch on This position is required for operation the ignition circuit is cl...

Page 39: ...deactivate the black ignition key Possible states Ignition off OFF In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start The black igniti...

Page 40: ...alled immobilizer indicator lamp 1 flashes when the alarm system is switched on Info The ignition key contains electronic components Never attach multiple ignition keys to a single key ring this may c...

Page 41: ...ehicle can roll away or fall over Park the vehicle on a firm and level surface 400732 01 Park the vehicle Turn the handlebar all the way to the left Insert the key into the ignition handlebar lock pre...

Page 42: ...r cap Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Sw...

Page 43: ...inse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out o...

Page 44: ...reak if overloaded Damaged ignition keys must be replaced Push down on the filler cap to take pressure off the igni tion key Turn ignition key 2 clockwise Fold open filler cap 3 6 11 Closing the fille...

Page 45: ...ses Warning Fire hazard Fuel is highly flammable toxic and a health hazard Check the filler cap is locked correctly after clos ing Change your clothing in case of fuel spills on them Rinse the affecte...

Page 46: ...move the fuel tank Possible states Fuel cocks are closed Level equalization cannot take place and the fuel supply to the throttle valve body is shut off Fuel cocks are open Level equalization can take...

Page 47: ...4 Closing the storage compartment S01757 11 Press cover 1 downward The lock engages audibly 6 15 Seat lock S01764 10 The seat lock 1 is located on the left side of the vehicle It can be unlocked using...

Page 48: ...7 Luggage rack plate S01766 10 The luggage rack plate 1 is located behind the seat The base plate of a luggage system optional can be attached to the luggage rack plate The luggage rack plate may not...

Page 49: ...e attached on the case holders Use case systems approved and or recommended by KTM Observe the specifications in the enclosed KTM PowerParts fitting instructions Info The use of other case systems is...

Page 50: ...enger footrests are foldable Possible states Passenger footrest folded in For operation without a passen ger Passenger footrest folded out For operation with a passen ger 6 20 Shift lever 402299 10 Th...

Page 51: ...itions can be seen in the figure The idle position is between the first and second gears 6 21 Foot brake lever 402301 10 Foot brake lever 1 is located in front of the right footrest The rear brake is...

Page 52: ...d up during motorcycle use The side stand is coupled with the safety starting system See the instructions in the Stopping parking chapter Possible states Side stand folded out The vehicle can be suppo...

Page 53: ...Indicator lamps p 55 7 2 Activation and test 402342 01 Activation The combination instrument is activated when the ignition is switched on Test The segment display the indicator lamps and the tachome...

Page 54: ...ator lamp lights up stop taking care not to endanger yourself or other road users in the process and contact an authorized KTM workshop The oil pressure warning lamp always lights up as long as the en...

Page 55: ...ng the indicator lamps p 55 the general warning light lights up the corresponding message appears in the matrix display The SET button is used to confirm receipt of the information and the message is...

Page 56: ...e indicator from constantly moving while riding The fuel level display is not updated while the side stand is folded out or the emergency off switch is switched off Once the side stand is folded up an...

Page 57: ...king care not to endanger yourself or other road users in the process and contact an authorized KTM workshop The oil pressure warning lamp always lights up as long as the engine is not running If the...

Page 58: ...ng safety warning note message was detected This is also shown on the matrix display The left turn signal lamp flashes green with a steady rhythmic flash The left turn signal is switched on The idle i...

Page 59: ...l message General message on operating safety Visit an authorized KTM workshop ABS warning ABS is not available Visit an autho rized KTM workshop Traction control Traction control is not available Vis...

Page 60: ...is dwindling Refuel at the next opportunity Icy road symbol The roads may be icy Adjust your speed to the road conditions Battery voltage The battery voltage is too low Recharge the battery with a su...

Page 61: ...shift warning light flashes over RPM1 and lights up continuously over RPM2 Info In sixth gear the shift warning light is deactivated when the engine is warm after the first service The shift warning l...

Page 62: ...The exact service intervals can be found in the service schedule 7 10 Matrix display menu 7 10 1 Favorites 401988 01 Press the UP or DOWN button until the Favorites menu appears on the matrix display...

Page 63: ...stops Trip 1 runs continuously and counts the distance up to 9999 Speed 1 indicates the average speed based on Trip 1 and Trip Time 1 Cons 1 indicates the average fuel consumption based on Trip 1 and...

Page 64: ...and counts the distance up to 9999 Speed 2 indicates the average speed based on Trip 2 and Trip Time 2 Cons 2 indicates the average fuel consumption based on Trip 2 and Trip Time 2 Trip Time 2 indicat...

Page 65: ...distance covered Battery displays the battery voltage Oil Temp inoperative 7 10 5 Set Favorites 401991 01 Condition The vehicle is stationary Press the UP or DOWN button until the Set Favorites menu a...

Page 66: ...s or various values are made in the Settings menu Several functions can be enabled or disabled 7 10 7 Warning L01435 10 Condition Message or warning Press the UP or DOWN button until the Warning menu...

Page 67: ...ect a heating level or to switch off the heated grips 7 10 9 MTC ABS L01436 10 Condition The vehicle is stationary Warning Voiding of the government approval for road use and the insurance coverage If...

Page 68: ...s enabled ABS only controls the front wheel The rear wheel is not controlled by ABS and may lock during braking maneuvers 7 10 10 Drive Mod 402432 01 Press the UP or DOWN button until the Drive Mod me...

Page 69: ...action control allows normal slip on the rear wheel RAIN reduced homologated performance for better rid ability the traction control allows normal slip on the rear wheel OFFROAD reduced homologated pe...

Page 70: ...7 COMBINATION INSTRUMENT 68 7 10 11 menu overview F00707 01...

Page 71: ...sages Heating optional MTC ABS Drive Mod 7 10 12 Language 402431 10 Condition The vehicle is stationary Press the UP or DOWN button until the Settings menu appears on the matrix display Pressing the S...

Page 72: ...matrix display Pressing the SET button again sets the unit of measure Select kilometers km or miles mi for the distance 7 10 14 Temp 402431 12 Condition The vehicle is stationary Press the UP or DOWN...

Page 73: ...the matrix display Pressing the SET button again sets the unit of measure Select bar or psi as the unit 7 10 16 Fuel Cons 402431 14 Condition The vehicle is stationary Press the UP or DOWN button unti...

Page 74: ...on again opens the menu Use the UP or DOWN button to navigate through the menu Use the SET button to set the time and date If the battery was removed the time and date must be set in the matrix displa...

Page 75: ...warning light lights up continuously Switch the Shift Light function on or off 7 10 19 Heat Grip L01439 15 Condition The vehicle is stationary Press the UP or DOWN button until the Settings menu appea...

Page 76: ...t is not a substitute for the low beam Automatic switching between the daytime running light and low beam may only be partially available when visibility is significantly impaired due to fog snow or r...

Page 77: ...TRUMENT 7 75 Press the UP or DOWN button until DRL is highlighted in black on the matrix display Pressing the SET button again switches the daytime running light on or off Switch the daytime running l...

Page 78: ...n two different positions In this way the handlebar can be mounted in the position that is most comfortable for the rider 8 2 Adjusting the handlebar position Warning Danger of accidents A repaired ha...

Page 79: ...emove screws 2 Take off the handlebar supports Place the handlebar supports in the required position Mount and tighten screws 2 Guideline Screw handle bar support M10 40 Nm 29 5 lbf ft Loctite 243 Inf...

Page 80: ...Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Info Make sure the gap widths are even 8 3 Adjusting the wind shield S01768 10 Pull the clamping lever 1 in the direction of the arrow The windshi...

Page 81: ...ERGONOMICS 8 79 S01769 10 Move the wind shield in the required position S01768 11 Push the clamping lever 1 in the direction of the arrow The windshield is locked...

Page 82: ...1 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 leve...

Page 83: ...brake lever to your hand size by turning adjusting wheel 1 Info Push the hand brake lever forward and turn the adjust ing wheel Do not make any adjustments while riding 8 6 Rider footrests M00621 10...

Page 84: ...e left and right sides M00622 10 Remove screw 1 The foot brake lever swings up to the stop M00640 10 Remove cotter pin 2 with washer 3 Carefully remove the pin 4 of the rider footrest Info The spring...

Page 85: ...ERGONOMICS 8 83 M00641 10 Remove screws 6 M00623 01 Adjust the footrest bracket to the desired position...

Page 86: ...Mount and tighten screws 6 Guideline Screw front footrest bracket M8 25 Nm 18 4 lbf ft Loctite 243 M00642 10 Mount the rider footrest with spring 5 and pin 4 Footrest spring plier 58429083000 Mount w...

Page 87: ...f push rod on foot brake cylin der M6 10 Nm 7 4 lbf ft Loctite 243 8 8 Checking the basic position of the shift lever Info When driving the shift lever must not touch the driver s boot when in the bas...

Page 88: ...e of your boot and the shift lever Distance between shift lever and upper edge of boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the basic position of the shift lever p...

Page 89: ...on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle components during the shift...

Page 90: ...individ ual requirements turn ball joint 4 accordingly Info The range of adjustment is limited The screw must be screwed into the ball joint by at least 5 turns Hold ball joint 4 and tighten nut 2 Gu...

Page 91: ...et boots gloves as well as trousers and a jacket with protectors on all rides Always wear protective clothing that is in good condition and meets the legal regulations Warning Danger of crashing Diffe...

Page 92: ...t 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 and...

Page 93: ...ly opening the throttle Info If the maximum engine speed is exceeded before the first service the shift warning light flashes 9 3 Loading the vehicle Warning Danger of accidents Total weight and axle...

Page 94: ...r other baggage Maximum speed with luggage 150 km h 93 2 mph Warning Danger of accidents The luggage system will be damaged if it is overloaded Read the manufacturer information on maximum payload whe...

Page 95: ...ch a way that it cannot be burned or singed by the hot exhaust system If you are carrying baggage make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight...

Page 96: ...d level p 181 Check the front brake linings p 180 Check the rear brake linings p 185 Check that the brake system is functioning properly Check the coolant level in the compensating tank p 241 Check th...

Page 97: ...ngine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Caution Danger of accidents Electronic components and safety devices will be damaged if the ba...

Page 98: ...ON After you switch on the ignition you can hear the fuel pump working for about two seconds The function check of the combination instrument is run at the same time The ABS indicator lamp lights up a...

Page 99: ...ectric starter button for at most 5 sec onds Wait for a least 5 seconds before trying again This motorcycle is equipped with a safety starting sys tem You can only start the engine if the transmission...

Page 100: ...g Danger of accidents If you change down at high engine speed the rear wheel blocks and the engine races Do not change into a low gear at high engine speed Warning Danger of accidents An incorrect ign...

Page 101: ...ning Danger of accidents A risky riding style constitutes a major risk Comply with traffic regulations and ride defensively and with foresight to detect sources of danger as early as possible Warning...

Page 102: ...loads Warning Danger of accidents Pieces of luggage which have slipped impair the handling characteristic Check that your luggage is fixed properly at regular intervals Warning Danger of accidents A f...

Page 103: ...e riding stop immediately switch off the engine and contact an authorized KTM workshop 402299 11 Shift into a higher gear when conditions allow incline road situation etc Release the throttle while si...

Page 104: ...to 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 electric starter button You do no...

Page 105: ...ip the matrix display shows a message for 10 seconds Info Very important messages are stored in the Warning menu If the icy road symbol appears in the combination instru ment the roads may be icy Adju...

Page 106: ...drag continuously Take your foot off the foot brake lever when you are not braking Warning Danger of accidents Higher total weight increases the stopping distance Take the longer stopping distance int...

Page 107: ...with luggage loaded with a high center of gravity varying road surfaces steep descents or full braking without disengaging the gear Adapt your riding style to the road conditions and your driving abi...

Page 108: ...ess and the brakes do not overheat 10 6 Stopping parking Warning Risk of injury People who act without authorization endanger themselves and others Do not leave the vehicle unattended if the engine is...

Page 109: ...firm and level surface Ensure that nobody sits on the vehicle when the vehicle is parked on a stand Apply the brakes on the motorcycle Shift the transmission to idle Switch off the ignition by turning...

Page 110: ...move the handlebar a little to the left and right Remove the black ignition key 10 7 Transporting Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and lev...

Page 111: ...Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the...

Page 112: ...he eyes Change your clothing in case of fuel spills on them Note Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged In some countries and regions the available fu...

Page 113: ...0 Switch off the engine Open the filler cap p 40 Fill the fuel tank with fuel up to the lower edge A of the filler neck Total fuel tank capacity approx 23 l 6 1 US gal Super unleaded ROZ 95 RON 95 PON...

Page 114: ...date service schedule can always be found on KTM Dealer net Your authorized KTM dealer will be happy to advise you 11 2 Required work Every two years Every year every 30 000 km 18 600 mi every 15 000...

Page 115: ...the hydraulic clutch p 142 Check the shock absorber and fork for leaks Perform service as needed and depending on how the vehicle is used Clean the dust boots of the fork legs p 158 Check the play of...

Page 116: ...Change the air filter clean the air filter box Check the fuel pressure Check the CO adjustment using the KTM diagnostics tool Check the headlight setting p 231 Check that the radiator fan is function...

Page 117: ...h lubrication Check the swingarm bearing for play Check the wheel bearing for play Grease all moving parts e g side stand hand lever chain and check for smooth operation Empty the drainage hoses Check...

Page 118: ...setting are shown in table 1 The table is found on the left inside cover of the fuel tank These adjustments are guidelines and should always be the basis for a suspension setting If the guidelines are...

Page 119: ...is located in left fork leg COMP white adjusting screw The rebound damping is located in right fork leg REB red adjusting screw Turn counterclockwise by the number of clicks corresponding to the fork...

Page 120: ...ill go Info Adjusting screw 1 is located at the upper end of the right fork leg The rebound damping is located in right fork leg REB red adjusting screw The compression damping is located in left fork...

Page 121: ...he spring pretension of the fork S01775 10 Turn adjusting screws 1 counterclockwise all the way Info Make the same adjustment on both fork legs Turn clockwise by the number of turns corresponding to t...

Page 122: ...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 eff...

Page 123: ...d with highly compressed nitrogen Please follow the description provided Your authorized KTM workshop will be glad to help Info The effect of the low speed setting can be seen in slow to normal compre...

Page 124: ...Adjusting the high speed compression damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorber...

Page 125: ...fo Do not loosen fitting 2 Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort 1 5 turns Standard 1 5 turns Sport 1 t...

Page 126: ...ed nitrogen Please follow the description provided Your authorized KTM workshop will be glad to help S01780 10 Turn adjusting screw 1 clockwise up to the last perceptible click Turn counterclockwise b...

Page 127: ...ckwise as far as it will go Turn it clockwise by the number of turns corresponding to the shock absorber type and use Guideline Spring preload Comfort 12 turns Standard 12 turns Sport 12 turns Full pa...

Page 128: ...s on the swingarm Insert the adapter in the rear lifting gear Universal V adapter with bushings 61029955144 Rear wheel work stand 69329955000 Place the motorcycle vertically use the adapters to direct...

Page 129: ...he side stand 1 Remove the lifting bushings from the swingarm 13 3 Lifting the motorcycle with the front lifting gear Note Danger of damage The parked vehicle can roll away or fall over Park the vehic...

Page 130: ...tem Mounting pin 69329965040 Front wheel work stand large 69329965000 Align the front lifting gear with the fork legs Info Always raise the motorcycle at the rear first Lift the motorcycle at the fron...

Page 131: ...gainst falling over Remove the front lifting gear Finishing work Install the bottom triple clamp cover p 147 13 5 Raising the motorcycle with the work stand inserted Note Danger of damage The parked v...

Page 132: ...ootrests and secure them Allow the work stand 1 with plastic bushing to engage in the opening of the swingarm pivot Work stand 62529055100 Info Set the work stand to an appropriate height and width Ra...

Page 133: ...VICE WORK ON THE CHASSIS 13 131 13 6 Removing the motorcycle from the work stand inserted Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surfa...

Page 134: ...falling over Remove special tool 1 Work stand 62529055100 Info To avoid damaging components lower the motorcycle slowly from the work stand The assistance of a second person can be useful Lean the mo...

Page 135: ...pull the seat back and lift it off Remove the ignition key 13 8 Mounting the seat 0 0 2 2 0 0 1 1 401677 10 Hook the catch 1 of the seat onto the fuel tank lower the rear and push it forward Insert th...

Page 136: ...4 13 10 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip Remove the lubricant from the tires using a suitable cleaning agent Warning Danger of accidents...

Page 137: ...le regulations Info The service life of the chain depends largely on its maintenance Preparatory work Raise the motorcycle with the rear lifting gear p 126 400725 01 Main work Rinse off loose dirt wit...

Page 138: ...ay fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the speci...

Page 139: ...d results in accidents If the chain is tensioned too much the chain engine sprocket rear sprocket transmission and rear wheel bearings wear more quickly Some components may break if overloaded If the...

Page 140: ...on the left and right so that the markings on the left and right chain adjusters 4 are in the same position relative to the reference marks A The rear wheel is then correctly aligned Info The upper p...

Page 141: ...cycle from the lifting gear p 126 13 13 Checking the chain rear sprocket and engine sprocket Preparatory work Raise the motorcycle with the rear lifting gear p 126 100132 10 Main work Check the rear s...

Page 142: ...Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance B from 18 chain rollers at the longest chain section 272 mm 10 71 in If distance...

Page 143: ...edge of the recess of the chain sliding guard Change the chain sliding guard Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the screws on the chain sl...

Page 144: ...ng the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch facing discs Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and...

Page 145: ...er 2 with membrane 3 Check the fluid level Fluid level below container rim 4 mm 0 16 in If the fluid level does not meet specifications Correct the fluid level of the hydraulic clutch Brake fluid DOT...

Page 146: ...eristic and dam ages components Correct incorrect steering head bearing play immediately Your authorized KTM workshop will be glad to help Info If the vehicle is operated for a lengthy period with pla...

Page 147: ...on the steering head bearing If there is detectable play Adjust the steering head bearing play Move the handlebar back and forth over the entire steering range It must be possible to move the handleba...

Page 148: ...HE CHASSIS 146 13 16 Removing the bottom triple clamp cover M00557 10 Remove screws 1 Lower triple clamp cover 2 slightly M00558 10 Disconnect plugs 3 of the horn Detach temperature sensor 4 Remove th...

Page 149: ...7 Installing the bottom triple clamp cover M00558 11 Plug in connectors 1 of the horn Attach temperature sensor 2 M00557 11 Position the triple clamp cover 3 Mount and tighten screws 4 Guideline Remai...

Page 150: ...13 SERVICE WORK ON THE CHASSIS 148 13 18 Removing the front side cover S01786 10 Remove screw 1 S01787 10 Remove screws 2 Remove side cover 3 Repeat these steps on the opposite side...

Page 151: ...13 19 Installing the front side cover S01788 10 Position the side cover in the area A under the tank cover S01789 10 Attach catch 1 of the side cover to bracket 2 and position on the fuel tank The ho...

Page 152: ...ver part M5 3 5 Nm 2 58 lbf ft S01790 10 Mount and tighten screws 6 Guideline Screw cover part M5 3 5 Nm 2 58 lbf ft Repeat these steps on the opposite side 13 20 Removing the mask spoiler Preparatory...

Page 153: ...SERVICE WORK ON THE CHASSIS 13 151 S01791 10 Main work Remove screw 1 S01792 10 Remove screw 2...

Page 154: ...13 SERVICE WORK ON THE CHASSIS 152 S01793 10 Loosen holding lug 3 from the inside cover S01794 10 Remove the mask spoiler laterally from the supports...

Page 155: ...WORK ON THE CHASSIS 13 153 S01795 10 Pull the mask spoiler upward from bracket 4 S01796 10 Disconnect plug in connector 5 Remove the mask spoiler with the turn signal Repeat the operation on the oppos...

Page 156: ...ORK ON THE CHASSIS 154 13 21 Installing the mask spoiler S01796 11 Main work Connect plug in connector 1 S01795 11 Position the mask spoiler in bracket 2 Info Ensure that the turn signal cable is plac...

Page 157: ...SERVICE WORK ON THE CHASSIS 13 155 S01794 11 Press the mask spoiler laterally into the supports S01793 10 Position holding lug 3 in the drill hole...

Page 158: ...ne Screw mask spoiler M5x17 3 5 Nm 2 58 lbf ft S01791 11 Mount and tighten screw 5 Guideline Screw mask spoiler M5x17 3 5 Nm 2 58 lbf ft Repeat the operation on the opposite side Finishing work Instal...

Page 159: ...and cable Remove screws 2 Take the fender off to the front Info Pay attention to the brake lines and the cable 13 23 Installing front fender S01797 11 Position the fender Info Pay attention to the ro...

Page 160: ...rcycle with the rear lifting gear p 126 Remove the bottom triple clamp cover p 146 Lift the motorcycle with the front lifting gear p 127 S01860 10 Main work Push dust boots 1 of both fork legs downwar...

Page 161: ...brake cleaner when nec essary Clean and oil the dust boots and inner fork tubes of both fork legs Universal oil spray p 292 Press the dust boots back into their installation position Remove excess oil...

Page 162: ...K ON THE CHASSIS 160 13 25 Removing the tank cover Preparatory work Remove the seat p 133 Remove the front side cover p 148 S01798 10 Main work Remove screw 1 Remove screw 2 S01799 10 Remove screw 3 R...

Page 163: ...SERVICE WORK ON THE CHASSIS 13 161 S01800 10 Remove screw 5 S01801 01 Raise the tank cover at the rear and take it off in a forward direction...

Page 164: ...lling the tank cover S01802 10 Main work Position the tank cover The catch 1 engages under the tank 2 Info Pay attention to the sealing lip and the bleeder hose S01800 11 Mount and tighten screw 3 Gui...

Page 165: ...lbf ft Mount and tighten screw 5 Guideline Screw cover part M5 3 5 Nm 2 58 lbf ft S01798 11 Mount and tighten screw 6 Guideline Screw cover part M6 6 Nm 4 4 lbf ft Mount and tighten screw 7 Guideline...

Page 166: ...SSIS 164 13 27 Removing the wind shield S01803 10 Remove screws 1 and wind shield 2 13 28 Installing the wind shield S01803 11 Position wind shield 1 Mount and tighten screws 2 Guideline Screw wind sh...

Page 167: ...emoving the engine guard S01804 10 Remove screws 1 with bushings and engine guard 2 13 30 Installing the engine guard S01804 11 Position engine guard 1 mount screws 2 with bushings and tighten Guideli...

Page 168: ...13 SERVICE WORK ON THE CHASSIS 166 13 31 Removing the crash bar D03196 10 Remove fittings 1 D03197 10 Remove screws 2 and take off the clamp halves...

Page 169: ...SERVICE WORK ON THE CHASSIS 13 167 D03198 10 Remove screw 3 Remove screw 4 Take off the left crash bar D03199 10 Remove screws 5 and take off the clamp halves...

Page 170: ...h bar D03200 11 Position the right crash bar with the frame protector The tank holding rubber should be correctly positioned on the fuel tank Info Cover the components to protect them against damage M...

Page 171: ...ten yet Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft D03198 11 Position the left crash bar with the frame protector The tank holding rubber should be correctly positioned on the fuel tank In...

Page 172: ...7 4 lbf ft D03197 11 Mount screws 6 with clamp halves but do not tighten yet Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft D03196 11 Mount and tighten fittings 7 Guideline Remaining chassis s...

Page 173: ...SERVICE WORK ON THE CHASSIS 13 171 Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft Remaining chassis screws M10 45 Nm 33 2 lbf ft...

Page 174: ...ges to the vehicle impair the function of the ABS Only allow the rear wheel to spin with the front brake applied away from public road traffic if the ABS is switched off Do not make any changes to the...

Page 175: ...s when driving straight ahead without the influence of lateral forces Warning Danger of accidents Driving aids can only prevent a rollover within the physical limitations It is not always possible to...

Page 176: ...3 must light up after the ignition is switched on and go out after starting off If it does not go out after starting off or if it is lit while riding this indicates a fault in the ABS system In this c...

Page 177: ...18 10 Check the front and rear brake disc thickness at multiple points for the dimension A Info Wear will reduce the thickness of the brake disc at con tact surface 1 of the brake linings Brake discs...

Page 178: ...uid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake system and do not continue riding until the problem is...

Page 179: ...rake fluid p 177 14 4 Adding front brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified mark...

Page 180: ...nse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accident...

Page 181: ...uid attacks paint Only use clean brake fluid from a sealed container Preparatory work Check the front brake linings p 180 S01806 10 Main work Move the brake fluid reservoir mounted on the handlebar to...

Page 182: ...Ensure that worn out brake linings are replaced immediately Your authorized KTM workshop will be glad to help Warning Danger of accidents Damaged brake discs reduce the braking effect If the brake lin...

Page 183: ...rs for damage and cracking If there is wear or tearing Change the front brake linings 14 6 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause...

Page 184: ...vel in the brake fluid reservoir 1 If the fluid level reaches the MIN marking A Add rear brake fluid p 182 14 7 Adding rear brake fluid Warning Danger of accidents An insufficient brake fluid level wi...

Page 185: ...nse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accident...

Page 186: ...id and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container Preparatory work Check the rear brake linings p 185 S01808 10 Main work Remove screw cap 1 with membra...

Page 187: ...ng effect If the brake linings are not changed in time the brake lining carriers grind against the brake disc As a consequence the braking effect is greatly reduced and the brake discs are destroyed C...

Page 188: ...he rear lifting gear p 126 Remove the bottom triple clamp cover p 146 Lift the motorcycle with the front lifting gear p 127 V00006 10 Main work Place a load on the rear of the vehicle The front wheel...

Page 189: ...y Info Do not actuate the hand brake lever when the brake caliper has been removed K00540 10 Loosen screw 4 by several rotations Loosen screws 5 Press on screw 4 to push the wheel spindle out of the a...

Page 190: ...wheel is removed H02027 10 Remove spacers 6 15 2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of...

Page 191: ...ct surfaces A of the spacers Long life grease p 291 S01829 10 Insert wide spacer 2 on the left in the direction of travel Info Arrow B indicates the direction of travel of the front wheel The ABS sens...

Page 192: ...scs free of oil and grease Clean the brake discs with brake cleaner when nec essary Clean and lightly grease screw 3 and wheel spindle 4 Long life grease p 291 Jack up the front wheel into the fork po...

Page 193: ...the hand brake lever in the activated position The brake calipers straighten Tighten screws 5 on both brake calipers Guideline Screw front brake caliper M10 45 Nm 33 2 lbf ft Loctite 243 Remove the lo...

Page 194: ...fork a few times firmly The fork legs straighten Tighten screws 8 Guideline Screw fork stub M8 15 Nm 11 1 lbf ft Finishing work Install the bottom triple clamp cover p 147 15 3 Removing the rear wheel...

Page 195: ...HEELS TIRES 15 193 S01832 10 Main work Press the brake caliper onto the brake disc by hand in order to push back the brake pistons S01830 10 Remove screw 1 and pull wheel speed sensor 2 out of the hol...

Page 196: ...h the rear wheel forward as far as possible Take the chain off of the rear sprocket and place it on chain sprocket guard 6 Warning Danger of accidents Damaged brake discs reduce the braking effect Alw...

Page 197: ...es the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Warning Danger of accidents There is no braking effect to start with at...

Page 198: ...r Long life grease p 291 Clean and lightly grease wheel spindle and nut Long life grease p 291 Mount the rubber dampers and rear sprocket carrier on the rear wheel Place the rear wheel in the swingarm...

Page 199: ...osi tion Make sure that the chain adjusters are fitted correctly on the adjusting screws Guideline In order for the rear wheel to be correctly aligned the mark ings on the left and right chain adjuste...

Page 200: ...essure point Finishing work Remove the rear of the motorcycle from the lifting gear p 126 15 5 Checking the rear hub rubber dampers Info The engine power is transmitted from the rear sprocket to the r...

Page 201: ...ub S01837 10 Lay the rear wheel on a workbench with the rear sprocket fac ing upwards and insert the wheel spindle in the hub Check the rear sprocket play A Info Measure the play on the outside of the...

Page 202: ...d to help Warning Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling charac teristic Different tire tread patterns can make the vehicle significantly more...

Page 203: ...pressure influence the braking and handling characteristics of the vehicle Worn tires are particularly unfavorable on wet surfaces 400602 10 Check the front and rear tires for cuts run in objects and...

Page 204: ...anufacture and the last two digits the year of manu facture KTM recommends that the tires be changed after 5 years at the latest regardless of the actual state of wear If the tires are more than 5 yea...

Page 205: ...Mount the dust cap 15 8 Checking spoke tension Warning Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in sec ondary damage The spokes break due to bein...

Page 206: ...fo The frequency of the sound depends on the spoke length and spoke diameter If spokes of the same length and diameter vibrate with a different tone this is an indication that the spoke tensions diffe...

Page 207: ...a defective tube This greatly reduces the risk of a sudden loss in pressure The masses and moments of inertia of these wheels are smaller than in conventional spoke wheels with a tube This results in...

Page 208: ...unning lights using the menu before going on a ride or when stopped so that the low beam is switched on permanently Note the legal regulations regarding the daytime run ning light The daytime running...

Page 209: ...e battery Only charge batteries in well ventilated rooms Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes with water for at least 15 minutes an...

Page 210: ...k Pull locking mechanism 1 in the direction of the arrow Fold open cover 2 S01812 10 Disconnect negative cable 3 from the battery Disconnect positive cable 4 from the battery Take the battery and batt...

Page 211: ...n flames away from the battery Only charge batteries in well ventilated rooms Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes with water for a...

Page 212: ...must be opposite the poles Position the battery and battery case in the battery compart ment Position the positive cable 2 and mount and tighten the screw Guideline Screw battery termi nal M6 4 5 Nm 3...

Page 213: ...ELECTRICAL SYSTEM 16 211 S01813 10 Close the cover 4 and push down slightly The cover engages with an audible click Finishing work Mount the seat p 133 Set the time and date...

Page 214: ...a immediately with plenty of water in the event of contact with the skin Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and battery gases get into the e...

Page 215: ...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 over discharge and sulfating oc...

Page 216: ...L SYSTEM 214 S01811 10 Main work Pull locking mechanism 1 in the direction of the arrow Fold open cover 2 S01814 10 Disconnect both negative cables 3 of the battery to avoid damage to the motorcycle s...

Page 217: ...ential of the battery and to test the alternator With this device you cannot over charge the battery Charge the battery at no more than 10 of the capac ity specified on the battery housing Switch off...

Page 218: ...t both negative cables 3 to the battery Guideline Screw battery termi nal M6 4 5 Nm 3 32 lbf ft S01813 10 Close cover 4 and push down slightly The cover engages with an audible click Finishing work Mo...

Page 219: ...overload the electrical system Only use fuses with the required ampere value Do not bypass or repair fuses Preparatory work Switch off the ignition by turning the black ignition key to the position OF...

Page 220: ...nfo You can recognize a faulty fuse by a burned out fuse wire A A spare fuse 5 is located in the starter relay The main fuse protects all power consumers of the vehicle Install a new main fuse Fuse 58...

Page 221: ...new spare fuse into the starter relay to have it available when needed S01815 10 Position rear fairing 2 Mount and tighten screws 1 Guideline Screw cover part M5 3 5 Nm 2 58 lbf ft Finishing work Moun...

Page 222: ...the electrical system Only use fuses with the required ampere value Do not bypass or repair fuses Info The fuse box containing the fuses of individual power consumers is located under the seat Prepara...

Page 223: ...ELECTRICAL SYSTEM 16 221 S01818 10 Main work Open fuse box cover 1 S01819 10 Check the fuses Info You can recognize a faulty fuse by a burned out fuse wire A Remove the faulty fuse...

Page 224: ...t ACC1 Fuse 3 15 A ABS hydraulic unit Fuse 4 25 A ABS return pump Fuse 5 not assigned Use spare fuses with the correct rating only Fuse 58011109110 p 277 Fuse 58011109115 p 277 Fuse 58011109125 p 277...

Page 225: ...ch off the ignition by turning the black ignition key to the position OFF Remove the seat p 133 Remove the front side cover p 148 Remove the tank cover p 160 Remove the mask spoiler p 150 Remove the w...

Page 226: ...the headlight mask onto a soft cloth so that the head light is not damaged 16 8 Installing the headlight mask with the headlight S01821 11 Main work Connect plug in connector 1 of the headlight Check...

Page 227: ...n screws 2 Guideline Screw headlight M6 5 Nm 3 7 lbf ft Finishing work Install the wind shield p 164 Install the mask spoiler p 154 Install the tank cover p 162 Install the front side cover p 149 Moun...

Page 228: ...on the reflector Clean and degrease the bulbs before mounting Do not touch the bulbs with your bare hands Preparatory work Switch off the ignition by turning the black ignition key to the position OF...

Page 229: ...ctor 3 into the new headlight bulb Low beam H11 socket PGJ19 2 p 277 Position headlight bulb 2 into the bulb socket and turn it all the way clockwise The headlight bulb is locked into the bulb socket...

Page 230: ...to the heat and be deposited on the reflector Clean and degrease the bulbs before mounting Do not touch the bulbs with your bare hands Preparatory work Switch off the ignition by turning the black ign...

Page 231: ...or 2 into the new headlight bulb High beam H11 socket PGJ19 2 p 278 Position headlight bulb 1 into the bulb socket and turn it all the way clockwise The headlight bulb is locked into the bulb socket F...

Page 232: ...s before mounting Do not touch the bulbs with your bare hands S01858 10 Remove the screw on the front of the turn signal housing Carefully take off diffuser 1 Push bulb 2 lightly into the socket turn...

Page 233: ...ehicle on a horizontal surface in front of a light colored wall and make a mark at the height of the center of the low beam headlight Make another mark at a distance B under the first marking Guidelin...

Page 234: ...k does not meet specifications Adjust the headlight range p 232 16 13 Adjusting the headlight range Preparatory work Check the headlight setting p 231 Remove the bottom triple clamp cover p 146 S01826...

Page 235: ...amming key must only be used for activating and deactivating If a black ignition key is lost or needs to be replaced the individual black ignition keys need to be enabled or disabled using the orange...

Page 236: ...ignition by turning the orange programming key to the ON position Immobilizer indicator lamp lights up Switch off the ignition by turning the orange programming key to the OFF position Pull out the or...

Page 237: ...this case it flashes twice Switch off the ignition by turning the orange programming key to the OFF position Pull out the orange programming key The lost black ignition key is deactivated The existing...

Page 238: ...ck ignition keys including the orange programming key In this case it flashes once since all black ignition keys are deactivated Switch off the ignition by turning the orange programming key to the OF...

Page 239: ...on OFF Remove the black ignition key If two other black ignition keys are to be activated repeat the last steps with the respective ignition key If the last black ignition key was activated insert the...

Page 240: ...lamp lights up Switch off the ignition by turning the orange programming key to the OFF position Pull out the orange programming key Insert the black ignition key in the ignition lock Switch on the i...

Page 241: ...LECTRICAL SYSTEM 16 239 Info As soon as the fourth black ignition key has been activated programming is finished 16 15 Diagnostics connector F00730 10 Diagnostics connector 1 is located under the seat...

Page 242: ...aximum continuous load is therefore significantly lower than the value of the fuse Do not use a stronger fuse 16 17 ACC1 and ACC2 rear A00224 10 Installation location The rear power supplies ACC1 1 an...

Page 243: ...of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach o...

Page 244: ...evel must be between MIN and MAX If there is no coolant in the compensating tank Check the cooling system for leaks Info Do not start up the motorcycle Add coolant bleed the cooling system If the cool...

Page 245: ...e the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact...

Page 246: ...in work Remove cover 1 of the compensating tank S01827 01 Add coolant until the coolant reaches the specified level Guideline The coolant level must be between MIN and MAX Coolant p 287 Mount the cove...

Page 247: ...eel RAIN Reduced homologated performance for better ridabil ity the traction control allows normal slip on the rear wheel OFFROAD Reduced homologated performance for better rid ability the traction co...

Page 248: ...When traction control is switched off the rear wheel may spin during high acceleration and on surfaces with low grip After the ignition is switched back on traction control is enabled again Traction...

Page 249: ...zontal surface 401696 11 Main work Check the engine oil level in the engine oil level viewer Info After switching off the engine wait one minute before checking the level The engine oil level should b...

Page 250: ...ar oil get very hot when the motorcycle is ridden Wear suitable protective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Warning Environme...

Page 251: ...n work Stand the motorcycle on its side stand on a horizontal surface Place a suitable container under the engine Remove oil drain plugs 1 with the magnets O rings and oil screens S00334 10 Remove scr...

Page 252: ...the oil filter housing Lock ring plier 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing surface S01839 10 Insert new oil filter 4 Info Only insert the oil filter by...

Page 253: ...VICE WORK ON THE ENGINE 19 251 S00334 11 Mount and tighten screws 2 Guideline Remaining screws for engine M5 6 Nm 4 4 lbf ft 100773 12 Thoroughly clean magnets A and oil screens B of the oil drain plu...

Page 254: ...ling quantity available Engine oil Outside temperature 0 C 32 F 3 60 l 3 8 qt Engine oil SAE 10W 50 p 288 Engine oil Outside temperature 0 C 32 F Engine oil SAE 5W 40 p 289 Add the oil quantity quanti...

Page 255: ...ug 5 Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effec...

Page 256: ...nd par tial quantity approx Outside temperature 0 C 32 F Engine oil SAE 5W 40 p 289 Mount the screw plug Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconscious...

Page 257: ...poor quality engine oil results in premature wear to the engine The engine may be damaged if the engine oil level is too high Condition The engine is at operating temperature Preparatory work Stand th...

Page 258: ...e optimal engine performance it is not advisable to mix different engine oils KTM recommends changing the engine oil Mount the screw plug Danger Danger of poisoning Exhaust gases are toxic and inhal i...

Page 259: ...SERVICE WORK ON THE ENGINE 19 257 Finishing work Check the engine oil level p 247...

Page 260: ...tly on to electrical components connectors throttle cables or bearings Maintain a minimum distance between the nozzle of the pressure cleaner and the component Minimum clearance 60 cm 23 6 in Warning...

Page 261: ...a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the vehicle with water first If the vehicle was operated in road salt clean it with cold water Warm water would enhance the...

Page 262: ...etrated to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 134 Treat bare metal parts except for brake discs and exhaust sys tem with corrosion...

Page 263: ...nition steering lock tank lock and seat lock Universal oil spray p 292 20 2 Checks and maintenance steps for winter operation Info If you use the motorcycle in winter you must expect salt on the roads...

Page 264: ...after the parts are cooled down and while they are installed After riding on salted roads thoroughly wash the motor cycle with cold water and dry it well Treat the engine the swingarm and all other ba...

Page 265: ...n this way you can avoid long workshop waiting times at the start of the new season 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additi...

Page 266: ...rom 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 t...

Page 267: ...ressed Emergency OFF switch is off Press the emergency OFF switch to the position ON Operating error Carry out the start procedure p 95 The battery is discharged Recharge the battery p 212 Check the o...

Page 268: ...onnection of the fuel line Fault in fuel injection system Read out the fault memory using the KTM diagnostics tool Fuel quality is insufficient Add suitable fuel Engine dies during the trip Lack of fu...

Page 269: ...screens p 248 The battery is discharged A power consumer is connected to the socket ACC1 Disconnect the power consumer from the socket ACC1 Recharge the battery p 212 The hazard warning flasher is sw...

Page 270: ...0 rpm Control DOHC 4 valves per cylinder chain driven Valve valve plate diameter Intake 42 mm 1 65 in Exhaust 34 mm 1 34 in Valve clearance Exhaust at 20 C 68 F 0 25 0 30 mm 0 0098 0 0118 in Intake at...

Page 271: ...35 2nd gear 15 32 3rd gear 18 30 4th gear 20 27 5th gear 24 27 6th gear 27 26 Mixture preparation Electronically controlled fuel injection Ignition system Contactless controlled fully electronic igni...

Page 272: ...ozzle M5 2 Nm 1 5 lbf ft Loctite 243 Remaining screws for engine M5 6 Nm 4 4 lbf ft Screw bearing retainer M5 6 Nm 4 4 lbf ft Loctite 243 Screw bearing shells retaining bracket M5 6 Nm 4 4 lbf ft Loct...

Page 273: ...0 Nm 7 4 lbf ft Screw clutch spring M6 12 Nm 8 9 lbf ft Screw engine case M6x60 10 Nm 7 4 lbf ft Screw engine case M6x80 10 Nm 7 4 lbf ft Screw engine case M6x90 10 Nm 7 4 lbf ft Screw freewheel holde...

Page 274: ...nection M6 5 Nm 3 7 lbf ft Nozzle 100 M6x0 75 4 Nm 3 lbf ft Loctite 243 Plug crankshaft retainer M8 15 Nm 11 1 lbf ft Screw camshaft bearing support M8 10 9 Step 1 10 Nm 7 4 lbf ft Step 2 18 Nm 13 3 l...

Page 275: ...10 Nm 7 4 lbf ft Screw engine bearer M10 45 Nm 33 2 lbf ft Oil pressure sensor M10x1 10 Nm 7 4 lbf ft Plug cam lever axis M10x1 15 Nm 11 1 lbf ft Plug clutch lubrication M10x1 10 Nm 7 4 lbf ft Screw...

Page 276: ...Nm 8 9 lbf ft Screw rotor Expansion screw M12x1 5 115 Nm 84 8 lbf ft Spark plug M12x1 5 18 Nm 13 3 lbf ft Nut of engine sprocket M20x1 5 100 Nm 73 8 lbf ft Loctite 243 Oil drain plug M20x1 5 20 Nm 14...

Page 277: ...3 60 l 3 8 qt Engine oil SAE 10W 50 p 288 Engine oil Outside temperature 0 C 32 F Engine oil SAE 5W 40 p 289 23 3 2 Coolant Coolant 2 40 l 2 54 qt Coolant p 287 23 3 3 Fuel Total fuel tank capacity ap...

Page 278: ...220 mm 8 66 in rear 220 mm 8 66 in Brake system front Double disc brake with radially mounted four pot brake calipers floating brake discs rear Single disc brake with dual piston brake caliper float i...

Page 279: ...ed 250 mm 9 84 in Weight without fuel approx 214 kg 472 lb Maximum permissible front axle load 165 kg 364 lb Maximum permissible rear axle load 285 kg 628 lb Maximum permissible total weight 450 kg 99...

Page 280: ...V 10 W Tail light LED Brake light LED License plate lamp LED 23 6 Tires Front tire Rear tire 90 90 21 M C 54T M S TL Continental TKC 80 Twinduro 150 70 B 18 M C 70Q M S TL Continental TKC 80 Twinduro...

Page 281: ...licks Standard 12 clicks Sport 7 clicks Full payload 7 clicks Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks Spring preload Preload Adjuster Comfort 2 turns...

Page 282: ...l 24 17 fl oz Fork oil SAE 4 48601166S1 p 289 23 8 Shock absorber Shock absorber article number 15 18 7Q 25 Shock absorber WP Performance Systems 4618 DCC PA Compression damping low speed Comfort 20 c...

Page 283: ...s Standard 12 turns Sport 12 turns Full payload 18 turns Spring rate Soft 170 N mm 971 lb in Medium standard 180 N mm 1 028 lb in Hard 190 N mm 1 085 lb in Spring length 205 mm 8 07 in Gas pressure 10...

Page 284: ...Remaining screws chassis M5 5 Nm 3 7 lbf ft Screw brake line holder on frame M5 2 Nm 1 5 lbf ft Screw brake line holder on swingarm M5 5 Nm 3 7 lbf ft Screw cable channel M5 5 Nm 3 7 lbf ft Screw cabl...

Page 285: ...Screw angle sensor M6 6 Nm 4 4 lbf ft Loctite 243 Screw ball joint of push rod on foot brake cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw battery terminal M6 4 5 Nm 3 32 lbf ft Screw cable channel...

Page 286: ...ew magnetic holder on side stand M6 6 Nm 4 4 lbf ft Loctite 243 Screw rear brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw retaining bracket angle sensor M6 10 Nm 7 4 lbf ft Loctite 243 Screw voltag...

Page 287: ...footrest bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw steering damper M8 25 Nm 18 4 lbf ft Loctite 243 Screw steering damper clamp M8 12 Nm 8 9 lbf ft Screw steering stem M8 20 Nm 14 8 lbf ft Screw...

Page 288: ...da sensor M12x1 25 25 Nm 18 4 lbf ft Screw bottom shock absorber M14x1 5 80 Nm 59 lbf ft Thread greased Screw top shock absorber M14x1 5 80 Nm 59 lbf ft Thread greased Nut swingarm pivot M19x1 5 130 N...

Page 289: ...1 Coolant Guideline Only use high grade silicate free coolant with corrosion inhibitor additive for aluminum motors Low grade and unsuitable antifreeze causes corrosion deposits and frothing Do not us...

Page 290: ...for antifreeze protection dilution and miscibility compatibility with other coolants Recommended supplier Motorex COOLANT M3 0 Engine oil SAE 10W 50 Standard classification JASO T903 MA p 293 SAE p 2...

Page 291: ...er and that possess the corresponding properties Synthetic engine oil Recommended supplier Motorex Power Synt 4T Fork oil SAE 4 48601166S1 Standard classification SAE p 293 SAE 4 Guideline Use only oi...

Page 292: ...ies Super unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel wi...

Page 293: ...Recommended supplier Motorex Chain Clean Chain lube for road use Guideline Recommended supplier Motorex Chainlube Road Fuel additive Recommended supplier Motorex Fuel Stabilizer Long life grease Reco...

Page 294: ...ts Recommended supplier Motorex Moto Polish Shine Preserving materials for paints metal and rubber Recommended supplier Motorex Moto Protect Special cleaner for glossy and matte paint finishes metal a...

Page 295: ...vice intervals are demanded for automobile engines the focus for motorcycle engines is on high performance at high engine speeds In most motorcycle engines the transmission and clutch are lubricated w...

Page 296: ...Software which automatically switches the indicator off according to a time or travel distance counter DRL Daytime Running Light Light which enhances the visibility of the vehicle dur ing the day but...

Page 297: ...LIST OF ABBREVIATIONS 28 295 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 298: ...orange symbols indicate an error condition that requires prompt intervention Active driving aids are also represented by yellow or orange symbols The general warning lamp lights up yellow An operating...

Page 299: ...lights up blue The high beam is switched on The left turn signal lamp flashes green with a steady rhythmic flash The left turn signal is switched on The idle indicator lamp lights up green The transmi...

Page 300: ...ke fluid front brake adding 177 rear brake adding 182 Brake fluid level front brake checking 176 rear brake checking 181 Brake linings front brake checking 180 rear brake checking 185 Brake system 172...

Page 301: ...5 Language 69 matrix display 53 menu overview 68 message on the matrix display 57 MTC 65 overview 51 Pressure 71 segment display 53 service display 60 Set Favorites 63 Settings 64 shift warning light...

Page 302: ...closing 42 opening 40 Foot brake lever 49 basic position adjusting 88 Footrests adjusting 82 Fork 116 compression damping adjusting 116 dust boots cleaning 158 rebound adjusting 118 spring pretension...

Page 303: ...t installing 224 removing 223 Headlight setting checking 231 High beam bulb changing 228 Horn button 35 I Ignition key activating deactivating 233 Ignition lock 37 Immobilizer 38 Intended use 12 K Key...

Page 304: ...18 Owner s Manual 17 P Parking 106 Passenger footrest 48 Preparing for use advice on preparing for first use 89 after storage 264 checks and maintenance measures when preparing for use 94 Protective...

Page 305: ...parts 18 Spoke tension checking 203 Starting 95 Steering locking 39 unlocking 40 Steering head bearing play checking 144 Steering lock 37 Stopping 106 Storage 263 Storage compartment closing 45 openin...

Page 306: ...alling 147 removing 146 Troubleshooting 265 267 Tubeless tire system 205 Turn signal bulb changing 230 Turn signal switch 34 Type label 26 U Use definition 12 V Vehicle loading 91 View of vehicle fron...

Page 307: ...3213756en 3213756en 10 2017 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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KTM 1090 Adventure R, Owner'S Manual

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