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KTM 1190 ADVENTURE R, Owner'S Manual, Page: 188 / 229

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KTM 1190 ADVENTURE R Owner'S Manual Download Page 188

19

SERVICE WORK ON THE ENGINE

186

S00334-10

–

Remove screws

2

. Remove the oil filter cover

3

with the O-ring.

S00335-10

–

Pull oil filter

4

out of the oil filter housing.

Circlip pliers reverse (51012011000)

–

Completely drain the engine oil.

–

Thoroughly clean the parts and sealing surface.

S00336-10

–

Insert oil filter

4

.

–

Lubricate the O-ring of the oil filter cover. Mount the oil filter cover

3

.

Summary of Contents for 1190 ADVENTURE R

Page 1: ...OWNER S MANUAL 2014 1190 Adventure R USA Art no 3213108en...

Page 2: ......

Page 3: ...ely All specifications are non binding KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications prices colors forms materials services designs equipment etc...

Page 4: ...ccording 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 T V Management Service KTM S...

Page 5: ...24 4 1 View of vehicle front left side vehicle differs slightly from photo 24 4 2 View of vehicle rear right side vehicle differs slightly from photo 26 5 SERIAL NUMBERS 28 5 1 Chassis number 28 5 2...

Page 6: ...orites 56 7 9 7 Settings 56 7 9 8 Warnings 57 7 9 9 Heat Grip optional 57 7 9 10 MTC ABS 58 7 9 11 Drive Mode 58 7 9 12 Menu overview 60 7 9 13 Language 61 7 9 14 Distance 62 7 9 15 Temp 62 7 9 16 Vol...

Page 7: ...e rebound damping of the shock absorber 102 12 9 Adjusting the spring preload of the shock absorber 103 13 SERVICE WORK ON THE CHASSIS 105 13 1 Raising the vehicle with the center stand 105 13 2 Remov...

Page 8: ...158 16 5 Changing the main fuse 162 16 6 Changing the fuses in the fuse box 164 16 7 Removing the headlight mask with the headlight 166 16 8 Refitting the headlight mask with the headlight 167 16 9 Ch...

Page 9: ...201 23 3 Capacities 205 23 3 1 Engine oil 205 23 3 2 Coolant 205 23 3 3 Fuel 205 23 4 Chassis 205 23 5 Electrical system 207 23 6 Tires 208 23 7 Fork 208 23 8 Shock absorber 209 23 9 Chassis tighteni...

Page 10: ...standing In the interest of your own safety have these jobs performed by an authorized KTM workshop There your motorcycle will be optimally cared for by specially trained experts using the specialist...

Page 11: ...oads in the homologated version 2 2 Safety advice A number of safety instructions need to be followed to operate the vehicle safely Therefore read this manual carefully The safety instruc tions are hi...

Page 12: ...hat 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 Id...

Page 13: ...11...

Page 14: ...2 SAFETY ADVICE 12 2 4 Overview of labels 500295 10...

Page 15: ...sion tuning 2 Canada type label 3 Information on starting up 4 Information on emission control 5 Information on chain tension 6 Information on noise emission 7 USA type label 8 Technical Information 5...

Page 16: ...2 SAFETY ADVICE 14 500297 01 Canada type label 700210 01 Information on starting up...

Page 17: ...2 SAFETY ADVICE 15 500299 01 Information on emission control 500304 01 Information on chain tension...

Page 18: ...2 SAFETY ADVICE 16 500301 01 Information on noise emission 500302 01 USA type label...

Page 19: ...nc To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 888 327 4236 or visit the website www nhtsa dot gov or write to NHTSA Headquarters 1200 New Jersey Avenue SE West Buildin...

Page 20: ...ictorin Saint Bruno QC J3V 6B7 Phone 450 441 4451 x 4250 www ktmcanada com Different rights may apply according to national or regional legislation 2 9 Tampering warning Tampering with the noise contr...

Page 21: ...ness 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 Warnin...

Page 22: ...elf locking screws and nuts seals and seal rings O rings pins lock washers must be replaced by new parts Where thread lockers are used on screw connections e g Loctite follow the instructions for use...

Page 23: ...then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it as...

Page 24: ...d auxiliary substances such as fuel and lubricants as specified in the Owner s Manual 3 3 Spare parts accessories For your own safety only use spare parts and accessory products that are approved and...

Page 25: ...these exactly you will ensure a much longer service life for your motorcycle 3 5 Figures The figures contained in the manual may depict special equipment In the interest of clarity some components may...

Page 26: ...4 VIEW OF VEHICLE 24 4 1 View of vehicle front left side vehicle differs slightly from photo 500293 10...

Page 27: ...38 2 Clutch lever p 32 3 Tool set p 43 4 Grab handles p 44 5 Luggage rack plate p 44 6 Seat lock p 43 7 Passenger footrests p 45 8 Center stand p 47 9 Rider footrests p 71 10 Shift lever p 45 11 Side...

Page 28: ...4 VIEW OF VEHICLE 26 4 2 View of vehicle rear right side vehicle differs slightly from photo 500294 10...

Page 29: ...adjustment 4 Fork rebound adjustment 5 Emergency OFF switch p 36 6 Electric starter button p 37 7 Hand brake lever p 32 8 Storage compartment 9 Cooling system compensating tank 10 Foot brake lever p 7...

Page 30: ...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 500305 10 Type label USA 1 is affixed to the...

Page 31: ...1 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 32: ...IAL NUMBERS 30 5 4 Engine number S00261 10 The engine number 1 is stamped on the right side of the engine 5 5 Fork part number S00306 10 The fork part number 1 is stamped on the inner side of the fork...

Page 33: ...5 SERIAL NUMBERS 31 5 6 Shock absorber part number S00264 10 The shock absorber part number 1 is stamped on the upper part of the shock absorber...

Page 34: ...elf adjusting 6 2 Hand brake lever S00215 10 The hand brake lever 1 is fitted on the right side of the handlebar The hand brake lever is used to activate both the front brake and rear brake at the sam...

Page 35: ...6 4 Switch on the left side of the handlebar 6 4 1 Combination switch The combination switch is fitted on the left side of the handlebar S00224 10 Overview of the left combination switch 1 Light switc...

Page 36: ...4 3 Hazard warning flasher switch 602606 10 The hazard warning flasher switch 1 is fitted on the combination switch on the left The hazard warning flasher is used to indicate emergency situations Info...

Page 37: ...signal switch S00217 10 The turn signal switch 1 is fitted on the combination switch on the left Possible states Turn signal off Press the turn signal switch Turn signal left on Turn signal switch pre...

Page 38: ...ight side of the handlebar 6 5 1 Emergency OFF switch S00220 10 The emergency OFF switch 1 is fitted on the right side of the handlebar Possible states Emergency OFF switch off In this position the ig...

Page 39: ...e clamp Info The ignition may only be switched on using a black ignition key With the orange programming key you can activate or deactivate the black ignition key Possible states Ignition off OFF In t...

Page 40: ...ever attach multiple ignition keys to a single key ring this may cause mutual interference A lost black ignition key must be deactivated to prevent unauthorized persons from operat ing the vehicle The...

Page 41: ...must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean conta...

Page 42: ...reakage To take pressure off of the ignition key push down on the filler cap Damaged igni tion keys must be replaced Turn ignition key 2 clockwise Fold open filler cap 3 6 10 Closing the filler cap S0...

Page 43: ...ediately clean contaminated areas on the skin with soap and water Remove ignition key 2 and close cover 3 6 11 Fuel cocks S00341 10 A fuel cock 1 is located on each side of the fuel tank Info The fuel...

Page 44: ...Opening the storage compartment S00226 10 Press button 1 in the direction of the arrow and lift the cover at the same time 6 13 Closing the storage compartment S00226 11 Press down cover 1 until the l...

Page 45: ...14 Seat lock S00238 10 The seat lock 1 is located on the left side of the vehicle It can be unlocked using the ignition key 6 15 Tool set S00235 10 The tool set 1 is located in the storage compartment...

Page 46: ...The luggage rack plate 1 is located behind the seat The base plate of a luggage system optional can be attached to the luggage rack plate The luggage rack plate may not be loaded with more than the sp...

Page 47: ...ootrests can be folded up and down Possible states Passenger footrests folded up For operation without a passenger Passenger footrests folded down For operation with a passenger 6 19 Shift lever S0023...

Page 48: ...d for parking the motorcycle Info The side stand must be folded up during motorcycle use The side stand is coupled with the safety start system see the instructions in the Stopping parking chapter Pos...

Page 49: ...6 CONTROLS 47 6 21 Center stand S00258 10 In addition to the side stand the vehicle is equipped with a center stand 1...

Page 50: ...trument is activated when the ignition is switched on Info The brightness of the displays is controlled by a brightness sensor in the combina tion instrument Test The segment display the indicator lam...

Page 51: ...If the General warning lamp lights up among the indicator lamps p 50 the corre sponding message appears in the matrix display The Set button is used to confirm receipt of the information and the messa...

Page 52: ...lay The left turn signal lamp flashes green simultaneously with the turn signal The left turn signal is switched on The idle indicator lamp lights up green The transmission is shifted to idle The righ...

Page 53: ...w Switch off the engine immediately Contact an authorized KTM workshop Engine oil level The engine oil level is too low Check the engine oil level and correct it Tire air pressure The tire pressure is...

Page 54: ...or lights up when the transmission should be shifted In the Shift Light menu the engine speed for the shift warning light can be set The shift warning light flashes over RPM1 and lights up permanently...

Page 55: ...found in the service schedule 7 9 Matrix display menu 7 9 1 Favorites 401988 01 Press the UP or DOWN button until the Favorites menu appears on the matrix display Pressing the SET button opens the me...

Page 56: ...range with the fuel reserve Press and hold the button for 3 5 seconds All entries in the Trip 1 menu are cleared 7 9 3 Trip 2 401825 01 Press the UP or DOWN button until the Trip 2 menu appears on th...

Page 57: ...the battery voltage Oil Temp indicates the engine oil temperature 7 9 5 TPMS optional 401845 01 Press the UP or DOWN button until the TPMS menu appears on the matrix display Guideline Tire air pressur...

Page 58: ...WN button to select the menu Press the SET button to set the menu for quick selection In the Set Favorites menu the Favorites menu can be configured 7 9 7 Settings 401841 01 Condition The vehicle is s...

Page 59: ...n to navigate through the warnings In the Warnings menu warnings that occurred are displayed and stored until they are no longer active 7 9 9 Heat Grip optional 401838 01 Press the UP or DOWN button u...

Page 60: ...vated ABS can intervene on both wheels 7 9 11 Drive Mode 401829 01 Press the UP or DOWN button until the Drive Mode menu appears on the matrix display Pressing the SET button opens the menu Use the UP...

Page 61: ...59...

Page 62: ...7 COMBINATION INSTRUMENT 60 7 9 12 Menu overview 401992 01...

Page 63: ...messages are present Heat Grip optional MTC ABS Drive Mode 7 9 13 Language 401842 10 Condition The vehicle is stationary Press the UP or DOWN button until the Settings menu appears on the matrix displ...

Page 64: ...matrix dis play Pressing the SET button again sets the unit of measure Select kilometers km or miles mi for the distance 7 9 15 Temp 401842 12 Condition The vehicle is stationary Press the UP or DOWN...

Page 65: ...lay Pressing the SET button again sets the unit of measure Select liters or gallons for the fuel consumption display 7 9 17 Pressure 401842 14 Condition The vehicle is stationary Press the UP or DOWN...

Page 66: ...e UP or DOWN button to navigate through the menu Use the SET button to set the time and date If the battery was disconnected the time and date must be set in the matrix display 7 9 19 Fuel Cons 401842...

Page 67: ...me running light 7 9 21 Shift Light 401846 01 Condition The vehicle is stationary Press the UP or DOWN button until the Settings menu appears on the matrix display Pressing the SET button opens the me...

Page 68: ...be activated Info This function is not available in this model 7 9 23 Heat Grips 401842 21 Condition The vehicle is stationary Press the UP or DOWN button until the Settings menu appears on the matrix...

Page 69: ...e handlebar position x Warning Danger of accidents Handlebar breakage If the handlebar is bent or straightened it will cause material fatigue and the handlebar can break Always replace handlebar 30808...

Page 70: ...bar supports evenly Position the handlebar Info Make sure cables and wiring are positioned correctly Position the handlebar clamps Mount and evenly tighten screws 1 Guideline Screw handlebar clamp M8...

Page 71: ...8 ERGONOMICS 69 S00247 10 Move the wind shield in the required position S00342 11 Lock clamping lever 1 by pushing in the direction of the arrow...

Page 72: ...w 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 a...

Page 73: ...two positions Possible states Rider footrests low A Rider footrests high B 8 7 Adjusting the footrests x Info The operations are the same for the left and right sides S00248 10 Remove cotter pin 1 wit...

Page 74: ...NOMICS 72 S00249 10 Remove screws 5 S00250 10 Adjust the footrest bracket to the desired position S00249 10 Mount and tighten screws 5 Guideline Screw front footrest bracket M8 25 Nm 18 4 lbf ft Locti...

Page 75: ...in front of the right footrest The rear brake is activated using the foot brake lever 8 9 Adjusting the basic position of the foot brake lever x Warning Danger of accidents Brake system failure If th...

Page 76: ...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 Guideline R...

Page 77: ...distance A between the upper edge of your boot and the shift lever Distance between shift lever and upper edge of boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the bas...

Page 78: ...r on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle components during the shi...

Page 79: ...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...

Page 80: ...ndover Before your first trip read the entire Owner s Manual carefully Get to know the controls Adjust the motorcycle to your requirements as described in the Ergonomics chapter Get used to handling t...

Page 81: ...cure 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...

Page 82: ...A hot exhaust system can burn baggage Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system If you are carrying baggage make sure it is fixed firmly as close a...

Page 83: ...37 Check the front brake linings p 136 Check the rear brake linings p 140 Check that the brake system is functioning properly Check the coolant level in the compensating tank p 179 Check the chain for...

Page 84: ...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...

Page 85: ...smission is in neutral or if the clutch lever is pulled when a gear is engaged If the side stand is folded out and you shift into gear the engine stops Remove the motorcycle from the center stand or s...

Page 86: ...the minimum age of passengers Warning Danger of accidents Danger of accidents caused by dangerous driving Comply with traffic regulations and ride defensively and foresightedly to detect sources of d...

Page 87: ...hicle 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 di...

Page 88: ...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 t...

Page 89: ...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 continu...

Page 90: ...e road condi tions and your riding ability When braking release the throttle and apply the front and rear brakes at the same time Info When ABS is enabled you can achieve maximum braking power even on...

Page 91: ...ch as exhaust system radiator engine shock absorber and the brake system Allow these components to cool down before starting work on them Note Danger of damage The parked vehicle may roll away or fall...

Page 92: ...on at the ignition lock power continues to flow to most power consumers This discharges the battery You should therefore always switch off the engine with the ignition key the emergency OFF switch is...

Page 93: ...ar open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel t...

Page 94: ...elp 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...

Page 95: ...00 km 620 mi Read out the trouble code memory using the KTM diagnostics tool x Check the fuel pressure x Check the functioning of the electrical equipment Change the engine oil and filter clean the oi...

Page 96: ...sion p 109 Check the brake lines for damage and leakage Check the brake fluid level of the front brake p 134 Check the coolant level in the compensating tank p 179 Change the air filter Clean the air...

Page 97: ...setting p 172 Final check Check the vehicle for roadworthiness and take a test ride Read out the error memory after the test ride using the KTM diagnostics tool x Check the CO adjustment with the KTM...

Page 98: ...earing for play x Grease all moving parts e g side stand hand lever chain and check for smooth operation x Check all hoses e g fuel cooling bleeder drainage etc and sleeves for cracking leaks and inco...

Page 99: ...uidelines are not adhered to the riding characteristics could deteriorate particularly at high speeds 12 2 Adjusting the compression damping of the fork Info The hydraulic compression damping determin...

Page 100: ...ork Info The hydraulic rebound damping determines the fork suspension behavior S00263 10 Turn the red adjusting screw 1 all the way clockwise Info Adjusting screw 1 is located at the upper end of the...

Page 101: ...counterclockwise to reduce damping 12 4 Adjusting the spring preload of the fork S00260 10 Turn adjusting screws 1 counterclockwise all the way Info Make the same adjustment on both fork legs Turn clo...

Page 102: ...when riding over an asphalt edge the rear wheel suspension compresses quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses m...

Page 103: ...clicks Sport 8 clicks Full payload 8 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 12 7 Adjusting the high speed compression damping of the shock absorber Caut...

Page 104: ...ing high speed Comfort 1 5 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce damping 12 8 Adjusting the rebound damping...

Page 105: ...15 clicks Standard 10 clicks Sport 8 clicks Full payload 8 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 12 9 Adjusting the spring preload of the shock absorbe...

Page 106: ...go Turn it clockwise by the number of turns corresponding to the shock absorber type and use Guideline Spring preload Comfort 4 turns Standard 4 turns Sport 4 turns Full payload 16 turns Info Turn clo...

Page 107: ...ter stand The center stand or the frame may become damaged and the motorcycle may fall over Pull the motorcycle up onto the center stand at the grab handles S00307 10 Stand to the left of the vehicle...

Page 108: ...e vehicle tips off of the center stand activate the front brake to stop the vehi cle from rolling away Check that the center stand is folded all the way up 13 3 Removing the seat S00241 10 Insert the...

Page 109: ...wer the rear while pushing it for ward Insert locking pin 2 into the lock housing and push down the rear of the seat until the locking pin engages with a click Check that the seat is correctly mounted...

Page 110: ...nd 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 dispo...

Page 111: ...cases If the chain is too loose however it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine Ensure that the chain tension is correct and adjust it if nec...

Page 112: ...bearings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme case...

Page 113: ...and right chain adjusters 4 are in the same position in relation to reference marks C The rear wheel is then correctly aligned Info The upper part of the chain must be taut Chain wear is not always ev...

Page 114: ...t Preparatory work Raise the vehicle with the center stand p 105 100132 10 Main work Check the rear sprocket and engine sprocket for wear If the rear sprocket or engine sprocket is worn Change the pow...

Page 115: ...the chain Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance B at the longest chain section 272 mm 10 71 in If distance B is great...

Page 116: ...iding guard Change the chain sliding guard x Check the chain sliding guard for tightness If the chain sliding guard is loose Tighten the chain sliding guard Guideline Screw chain sliding guard M5 5 Nm...

Page 117: ...ing wear of the clutch lining disc Do not use brake fluid S00270 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 Che...

Page 118: ...ork Raise the vehicle with the center stand p 105 400738 11 Main work Place a load on the rear of the vehicle The front wheel is not in contact with the ground Move the handlebar to the straight ahead...

Page 119: ...ing the bottom triple clamp cover 202248 12 Remove screws 1 Plug out the horn Remove the triple clamp cover 2 13 13 Installing the bottom triple clamp cover x 202248 13 Position the triple clamp cover...

Page 120: ...13 SERVICE WORK ON THE CHASSIS 118 13 14 Removing the front side cover 307815 10 Remove screw 1 307816 10 Remove screws 2 Remove side cover 3 Repeat the operation on the opposite side...

Page 121: ...CHASSIS 119 13 15 Installing the front side cover 307817 10 Position the side cover in the A area under the tank cover 307818 10 Attach catch 1 and bracket 2 of the side cover to the fuel tank and po...

Page 122: ...art M5x12 3 5 Nm 2 58 lbf ft 307816 11 Mount and tighten screws 4 Guideline Screw cover part M5x12 3 5 Nm 2 58 lbf ft Repeat the operation on the opposite side 13 16 Removing the mask spoiler x Prepar...

Page 123: ...13 SERVICE WORK ON THE CHASSIS 121 307823 10 Main work Remove screw 1 307824 10 Remove screw 2 307825 10 Loosen holding lug 3 from the inside cover...

Page 124: ...2 307828 10 Remove the mask spoiler laterally from the supports 307826 10 Pull the mask spoiler upward from bracket 4 307827 10 Detach connector 5 Remove the mask spoiler with the turn signal Repeat t...

Page 125: ...E WORK ON THE CHASSIS 123 13 17 Installing the mask spoiler x 307827 11 Main work Plug in connector 1 307826 11 Position the mask spoiler in bracket 2 Info Ensure that the turn signal cable is placed...

Page 126: ...THE CHASSIS 124 307828 11 Press the mask spoiler laterally into the supports 307825 10 Position holding lug 3 in the drill hole 307824 11 Mount and tighten screw 4 Guideline Screw mask spoiler M5x17...

Page 127: ...ft Repeat the operation on the opposite side Finishing work Install the tank cover p 128 Install the front side cover p 119 Mount the seat p 107 13 18 Removing the front fender S00323 10 Remove holde...

Page 128: ...ion to where the brake lines are placed Mount and tighten screws 1 Guideline Screw fender M5x12 3 5 Nm 2 58 lbf ft Mount holder 2 with the brake line on the fender 13 20 Removing the tank cover Prepar...

Page 129: ...13 SERVICE WORK ON THE CHASSIS 127 307820 10 Remove screw 3 Remove screw 4 307821 10 Remove screw 5 307822 10 Raise the tank cover at the rear and remove it in a forward direction...

Page 130: ...Position the tank cover Info Note the sealing lip Mount and tighten screw 1 Guideline Screw cover part M5x12 3 5 Nm 2 58 lbf ft 307820 11 Mount and tighten screw 2 Guideline Screw cover part M6 6 Nm 4...

Page 131: ...Guideline Screw cover part M6 6 Nm 4 4 lbf ft Mount and tighten screw 5 Guideline Screw cover part M5x12 3 5 Nm 2 58 lbf ft Finishing work Install the front side cover p 119 Mount the seat p 107 13 2...

Page 132: ...13 SERVICE WORK ON THE CHASSIS 130 13 23 Installing the wind shield S00259 11 Position wind shield 1 Mount and tighten screws 2 Guideline Screw wind shield M5 3 5 Nm 2 58 lbf ft...

Page 133: ...air pressure differ ent brake linings etc the ABS will not function optimally Optimal function ing of the ABS is only ensured if the brake system only contains spare parts and tires that have been app...

Page 134: ...rates with two independent brake circuits front and rear brakes When the ABS control unit detects a locking tendency in a wheel ABS begins regulating the brake pressure The regulating process causes a...

Page 135: ...ness of the front and rear brake discs at multiple points on each brake disc to ensure it is at least thickness A Info Wear will reduce the thickness of the brake disc at the contact surface 1 of the...

Page 136: ...of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help S00269 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal posit...

Page 137: ...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 g...

Page 138: ...ke fluid immediately with water 14 5 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your aut...

Page 139: ...the rear brake fluid level 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 lini...

Page 140: ...m 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...

Page 141: ...es 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 Preparatory work Raise the ve...

Page 142: ...brake discs If the brake linings are not changed in time the steel brake lining carriers grind on the brake disc The braking effect is greatly reduced and the brake discs are destroyed Check the brak...

Page 143: ...n contact with the ground Remove screw 1 and pull wheel speed sensor 2 out of the hole S00314 10 Remove screws 3 from both brake calipers Press back the brake linings with a light lateral tilting of t...

Page 144: ...mp Remove screw 4 Warning Danger of accidents Reduced braking efficiency due to damaged brake discs Always lay down the wheel in such a way that the brake discs are not dam aged Holding the front whee...

Page 145: ...for damage and wear If the wheel bearing is damaged or worn Change the wheel bearing x Clean and grease the shaft seal rings 1 and contact surface A of the spacers Long life grease p 219 S00339 10 In...

Page 146: ...ront wheel spindle M25x1 5 45 Nm 33 2 lbf ft Thread greased S00314 11 Position the brake calipers and check that the brake linings are seated correctly Mount screws 5 on both brake calipers but do not...

Page 147: ...ssis screws M6 10 Nm 7 4 lbf ft Remove the vehicle from the center stand p 105 S00315 11 Pull the front brake and compress the fork forcefully a few times The fork legs straighten Tighten screws 8 Gui...

Page 148: ...10 Main work Press the brake caliper by hand on to the brake disc in order to press back the brake pistons S00277 10 Remove screw 1 and pull wheel speed sensor 2 out of the hole S00276 10 Remove nut...

Page 149: ...e rear wheel withdraw the wheel spindle Take the rear wheel out of the swing arm Info Do not operate the foot brake when the rear wheel is removed Remove the spacer 7 15 4 Installing the rear wheel x...

Page 150: ...life grease p 219 Clean and grease the thread of the wheel spindle and nut Long life grease p 219 Mount the rubber dampers and rear sprocket carrier in the rear wheel Place the rear wheel in the swing...

Page 151: ...eference marks B Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Thread greased S00289 10 Insert wheel speed sensor 6 into the hole Mount and tighten screw 7 Guideline Remaining chassis screws M6 10...

Page 152: ...d or worn Change all rubber dampers in the rear hub S00291 10 Lay the rear wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub Check the rear sprocket pl...

Page 153: ...ntrollable 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 acc...

Page 154: ...ires Info The tire s date of manufacture is usually part of the tire markings and is indi cated by the last four digits of the DOT marking The first two digits refer to the week of manufacture and las...

Page 155: ...rect the tire pressure Mount the dust cap 15 8 Checking spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that the spoke tension is correct Your authori...

Page 156: ...e frequency of the sound is a function of the spoke length and spoke diame ter If spokes of the same length and diameter vibrate with a different tone this is an indication that the spoke tensions dif...

Page 157: ...fo Note the legal regulations regarding the daytime running light 16 2 Removing the battery x Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of t...

Page 158: ...e engine Remove the seat p 106 S00302 10 Main work Pull locking mechanism 1 in the direction of the arrow Fold open cover 2 S00303 10 Disconnect negative cable 3 of the battery Disconnect the positive...

Page 159: ...s of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Caution Danger of accidents If the vehicle is operated with a discharged battery or without...

Page 160: ...rning 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 ac...

Page 161: ...he 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 saf...

Page 162: ...le s electronics 602678 01 Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 You can also use the battery charger to test the open circuit voltage an...

Page 163: ...and charging time must not be exceeded Charge the battery regularly when the motorcycle is not in use 3 months 602677 11 Connect both negative cables 3 Guideline Screw battery terminal M6 4 5 Nm 3 32...

Page 164: ...loaded if the wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Preparatory work Switch off all power consumers and switch off the engine Remove the seat p...

Page 165: ...consumers of the vehicle Install a new main fuse Fuse 58011109130 p 207 Check that the electrical equipment is functioning properly Mount protection covers Tip Insert a new spare fuse into the starter...

Page 166: ...e wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Info The fuse box containing the fuses of individual power consumers is located under the seat Preparat...

Page 167: ...ol units and components Fuse 2 10 A socket ACC1 Fuse 3 25 A ABS hydraulic unit Fuse 4 40 A ABS return pump Fuse 5 not used Use spare fuses with the correct rating only Fuse 58011109110 p 207 Fuse 5801...

Page 168: ...ff the engine Remove the seat p 106 Remove the front side cover p 118 Remove the tank cover p 126 Remove the mask spoiler x p 120 Remove the wind shield p 129 S00293 10 Main work Remove screws 1 Remov...

Page 169: ...lighting is functioning properly Position the headlight mask S00293 11 Mount and tighten screws 2 Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft Finishing work Install the wind shield p 130 In...

Page 170: ...efore mounting Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 106 Remove the front side cover p 118 Remove the tank cover p 126 Remove the mask spoiler x p...

Page 171: ...headlight p 167 Install the wind shield p 130 Install the mask spoiler x p 123 Install the tank cover p 128 Install the front side cover p 119 Mount the seat p 107 Check the headlight setting p 172 1...

Page 172: ...Push headlight bulb 1 lightly into the bulb socket turn it all the way counterclock wise and pull it out Disconnect plug 2 S00296 10 Plug connector 2 into the new headlight bulb High beam H11 socket...

Page 173: ...Clean the lamp and keep it free of grease before mounting B01860 10 Remove the screw on the front of the turn signal housing Carefully remove diffuser 1 Press bulb 2 carefully into the socket turn it...

Page 174: ...t a distance B under the first mark Guideline Distance B 5 cm 2 in Position the vehicle perpendicular to the wall at a distance A from the wall and switch on the low beam Guideline Distance A 5 m 16 f...

Page 175: ...wise to increase the headlight range turn counterclockwise to reduce the headlight range If you have a payload you may have to correct the headlight range 400726 11 Set the headlight to marking B Guid...

Page 176: ...on procedure are invalid but can be reprogrammed in a further activation procedure 401114 10 Loss of a black ignition key additional black ignition keys are available The following procedure deactivat...

Page 177: ...number of func tional black ignition keys including the orange programming key In this case it flashes twice Switch off the ignition by turning the orange programming key to the OFF position Pull out...

Page 178: ...e programming key All black ignition keys are deactivated Order a new black ignition key according to the key number on the KEYCODECARD and activate it To activate up to three black ignition keys Pres...

Page 179: ...nition keys Press the emergency OFF switch to the position ON Insert the orange programming key in the ignition lock Switch on the ignition by turning the orange programming key to the ON position Imm...

Page 180: ...16 ELECTRICAL SYSTEM 178 Info After the fourth black ignition key has been activated programming is fin ished...

Page 181: ...ith the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swallowed contact a physician immediately Change c...

Page 182: ...ater Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immedi atel...

Page 183: ...26 01 Add coolant until the coolant reaches the specified level Guideline The coolant level must be between MIN and MAX Alternative 1 Coolant p 214 Alternative 2 Coolant mixed ready to use p 214 Mount...

Page 184: ...menu You can choose from SPORT STREET RAIN and OFFROAD The drive mode selected last is displayed on the right in the segment display Info The drive mode selection has no influence on the ABS 18 2 MTC...

Page 185: ...18 ENGINE TUNING 183 Info When traction control is active the TC lamp flashes When traction control is switched off the TC lamp is lit...

Page 186: ...k the engine oil level in the engine oil level viewer Info After switching off the engine wait one minute before checking the level The engine oil level should be in the upper area B of the engine oil...

Page 187: ...rns 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 stipula...

Page 188: ...ith the O ring S00335 10 Pull oil filter 4 out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing surface S00336 10 Ins...

Page 189: ...2 Guideline Remaining engine screws M5 6 Nm 4 4 lbf ft 100773 12 Thoroughly clean magnet A and oil screen B of the oil drain plugs S00333 10 Mount and tighten oil drain plugs 1 with the magnet O ring...

Page 190: ...prox 3 0 l 3 2 qt Outside temperature 0 C 32 F Engine oil SAE 10W 50 p 215 Outside temperature 0 C 32 F Engine oil SAE 5W 40 p 215 Mount screw plug 5 Danger Danger of poisoning Exhaust gases are toxic...

Page 191: ...and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight Finishing work Check the engine oil level p 184...

Page 192: ...the engine oil level viewer Condition Outside temperature 0 C 32 F Engine oil SAE 10W 50 p 215 Condition Outside temperature 0 C 32 F Engine oil SAE 5W 40 p 215 Info In order to achieve optimal engin...

Page 193: ...sult 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 extra...

Page 194: ...e 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 sunshin...

Page 195: ...em to evaporate Push back the protection caps of the handlebar controls to allow any water that has penetrated to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings...

Page 196: ...after riding Warm water would enhance the corrosive effects of salt 401060 01 Clean the motorcycle p 192 Clean the brakes Info After EVERY trip on salted roads thoroughly wash the brake calipers and b...

Page 197: ...20 CLEANING CARE 195 Clean the chain p 108...

Page 198: ...ng for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 218 Refuel p 91 Clean the motorcycle p 192 Change the engine oil and filter clean the oil screens x p...

Page 199: ...the water vapor produced during combustion condenses and causes valves and the exhaust system to rust 21 2 Preparing for use after storage 401059 01 Remove the vehicle from the center stand p 105 Rech...

Page 200: ...echarge the battery x p 158 Check the quiescent current x Safety start system is faulty Read out the fault memory using the KTM diag nostics tool x ICU is not enabled Activate the ICU x CAN bus commun...

Page 201: ...up ABS fuse is blown Change the fuses in the fuse box p 164 Wheel speeds of front and rear wheels differ greatly Stop switch off the ignition start again Malfunction in ABS Read out the fault memory...

Page 202: ...aust 34 mm 1 34 in Valve clearance Exhaust at 20 C 68 F 0 25 0 30 mm 0 0098 0 0118 in Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Crankshaft bearing Sleeve bearing Conrod bearing Sleeve bearing...

Page 203: ...park plug NGK LMAR7A 9 Electrode gap spark plug 0 8 0 9 mm 0 031 0 035 in Cooling Water cooling permanent circulation of coolant by water pump Cold start device Electric starter 23 2 Engine tightening...

Page 204: ...2 Nm 8 9 lbf ft Screw coolant connection on cylinder head M6 10 Nm 7 4 lbf ft Screw damping plate M6 10 Nm 7 4 lbf ft Loctite 243 Screw engine case M6x60 10 Nm 7 4 lbf ft Screw engine case M6x80 10 Nm...

Page 205: ...Step 2 18 Nm 13 3 lbf ft Screw camshaft bearing support M8 10 9 Step 1 8 5 Nm 6 27 lbf ft Step 2 14 5 Nm 10 7 lbf ft Only applies when using Hex key bit 61229025000 Screw engine case M8 18 Nm 13 3 lb...

Page 206: ...Nm 22 1 lbf ft Step 3 90 Step 4 90 Lubricated with engine oil Coolant temperature sensor M12x1 5 12 Nm 8 9 lbf ft Rotor screw M12x1 5 90 Nm 66 4 lbf ft Spark plug M12x1 5 15 Nm 11 1 lbf ft Nut of engi...

Page 207: ...0 l 2 54 qt Coolant p 214 Coolant mixed ready to use p 214 23 3 3 Fuel Total fuel tank capacity approx 23 l 6 1 US gal Super unleaded ROZ 95 RON 95 PON 91 p 216 Fuel reserve approx 3 5 l 3 7 qt 23 4 C...

Page 208: ...4 5 mm 0 177 in Tire air pressure solo with passenger full payload Front with cold tires 2 4 bar 35 psi Rear with cold tires 2 9 bar 42 psi Secondary drive ratio 17 42 Chain 5 8 x 5 16 525 X ring Stee...

Page 209: ...Fuse 58011109110 10 A Fuse 58011109125 25 A Fuse 58011109130 30 A Fuse 58011109140 40 A Low beam H11 socket PGJ19 2 12 V 55 W High beam H11 socket PGJ19 2 12 V 55 W Parking light LED Instrument light...

Page 210: ...vailable in the Service section under http www ktm com 23 7 Fork Fork part number 14 18 8N 25 Fork WP Suspension 4860 MXTA SPLIT Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks...

Page 211: ...per fork leg 720 ml 24 34 fl oz Fork oil SAE 4 48601166S1 p 216 23 8 Shock absorber Shock absorber part number 15 18 7N 25 Shock absorber WP Suspension 4618 BAVP DCC PA Compression damping low speed...

Page 212: ...5 psi Riding sag 55 mm 2 17 in Static sag 25 mm 0 98 in Fitted length 406 mm 15 98 in Shock absorber oil p 216 SAE 2 5 23 9 Chassis tightening torques Screw combination switch left M4 2 Nm 1 5 lbf ft...

Page 213: ...m 4 4 lbf ft Nut ABS unit fixation M6 8 Nm 5 9 lbf ft Remaining chassis nuts M6 10 Nm 7 4 lbf ft Remaining chassis screws M6 10 Nm 7 4 lbf ft Screw battery terminal M6 4 5 Nm 3 32 lbf ft Screw brake l...

Page 214: ...ning chassis screws M8 25 Nm 18 4 lbf ft Screw bottom triple clamp M8 12 Nm 8 9 lbf ft Screw foot brake lever M8 25 Nm 18 4 lbf ft Loctite 243 Screw fork stub M8 15 Nm 11 1 lbf ft Screw front footrest...

Page 215: ...M10x1 12 Nm 8 9 lbf ft Loctite 243 Screw subframe M10x1 25 45 Nm 33 2 lbf ft Lambda 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...

Page 216: ...astrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant even in countries with high temperatures Using inferior antifreeze can result in corrosi...

Page 217: ...that possess the corresponding properties Fully synthetic engine oil Recommended supplier Motorex Power Synt 4T Engine oil SAE 5W 40 Standard classification JASO T903 MA p 220 SAE p 220 SAE 5W 40 Gui...

Page 218: ...draulic oil that complies with the specified standard see specifications on the container and that possesses the corre sponding properties Recommended supplier Motorex Hydraulic Fluid 75 Shock absorbe...

Page 219: ...aded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or...

Page 220: ...road use Guideline Recommended supplier Motorex Chainlube Road Cleaning and preserving materials for metal rubber and plastic Recommended supplier Motorex Moto Protect Fuel additive Recommended suppl...

Page 221: ...ke Grease 2000 Motorcycle cleaner Recommended supplier Motorex Moto Clean Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces Recommended supplier Motorex Quick...

Page 222: ...vice intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated wit...

Page 223: ...nings front brake checking 136 rear brake checking 140 Brake system 131 140 Brakes 87 Brakes applying 87 C Capacity coolant 205 engine oil 188 205 fuel 92 205 Center stand 47 Chain checking 112 checki...

Page 224: ...Temp 62 TPMS 55 Trip 1 54 Trip 2 54 Volume 63 Warnings 57 Combination switch 33 Overview 33 Coolant level compensating tank checking 179 compensating tank correcting 180 Customer service 23 E Electri...

Page 225: ...usting 70 Handlebar position 67 adjusting 67 Hazard warning flasher 34 Hazard warning flasher switch 34 Headlight daytime running light 155 headlight range adjusting 173 Headlight mask with headlight...

Page 226: ...for use advice on first use 77 after storage 197 checks and maintenance measures when preparing for use 81 Protective clothing 20 R Rear hub rubber dampers checking 149 Rear sprocket checking 112 Rear...

Page 227: ...ring head bearing play checking 116 Steering lock 37 Stopping 89 Storage 196 Storage compartment Closing 42 Opening 42 Suspension setting 97 104 Switch on the left side of the handlebar 33 on the righ...

Page 228: ...el 28 U Use definition 9 V Vehicle loading 79 raising with the center stand 105 removing from the center stand 105 View of vehicle front left 24 rear right side 26 W Warranty 22 Wind shield adjusting...

Page 229: ...3213108en 3213108en 10 2013 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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