KTM 1190 RC8 R EU/UK 2009 Owner'S Manual Download Page 188

Page: 188 / 283

BRAKE SYSTEM

186

B00578-10

–

Check all brake linings on both brake calipers to ensure they have minimum thick-
ness



Minimum thickness



≥

1 mm (

≥

0.04 in)

» If the minimum thickness is less than specified:

–

Change the front brake linings.

–

Check all brake linings on both brake calipers for damage and cracking.
» If damage or wear is encountered:

–

Change the front brake linings.

12.7

Checking 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 linings. Check

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

Warning

Danger of accidents

Reduced braking efficiency due to old brake fluid.

–

Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be
pleased to help.)

Summary of Contents for 1190 RC8 R EU/UK 2009

Page 1: ...OWNER S MANUAL 2015 1190 RC8 R US Art no 3213285en ...

Page 2: ......

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

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 TÜV Management Service KTM Sportmotorcycle GmbH 5230 Mattighofen Austria ...

Page 5: ... 4 VIEW OF VEHICLE 24 4 1 View of vehicle front left example 24 4 2 View of vehicle rear right example 26 5 SERIAL NUMBERS 28 5 1 Vehicle identification number type label 28 5 2 Key number 28 5 3 Engine number 29 5 4 Fork part number 29 5 5 Shock absorber article number 30 5 6 Steering damper part number 30 6 CONTROLS 31 6 1 Clutch lever 31 6 2 Hand brake lever 31 6 3 Throttle grip 32 6 4 Horn but...

Page 6: ...ton blank time LAP BLANK TIME menu 73 6 13 33 Number of laps menu SET NUM LAPS 74 6 13 34 Fuel reserve display menu TRIP F RESET 75 6 13 35 UNITS menu 77 6 13 36 Kilometers miles menu SET KM MILES 78 6 13 37 Temperature display menu SET C F 79 6 13 38 Fuel consumption menu liters SET FUEL CONS 80 6 13 39 Fuel consumption menu gallons SET GAL US UK 81 6 13 40 Additional functions menu OPTIONS 82 6 ...

Page 7: ...129 10 TUNING THE CHASSIS 132 10 1 Fork shock absorber 132 10 2 Adjusting the compression damping of the fork 132 10 3 Adjusting the rebound damping of the fork 133 10 4 Adjusting the spring preload of the fork 134 10 5 Compression damping of the shock absorber 135 10 6 Adjusting the low speed compression damping of the shock absorber 136 10 7 Adjusting the high speed compression damping of the sh...

Page 8: ...18 Correcting fluid level of hydraulic clutch 180 12 BRAKE SYSTEM 181 12 1 Adjusting the basic position of the hand brake lever 181 12 2 Checking the front brake discs 181 12 3 Checking the rear brake disc 182 12 4 Checking the front brake fluid level 183 12 5 Adding brake fluid of front brake 183 12 6 Checking the front brake linings 185 12 7 Checking the rear brake fluid level 186 12 8 Adding re...

Page 9: ...ng the oil filter 234 17 6 Filling up with engine oil 234 17 7 Adding engine oil 236 18 CLEANING CARE 238 18 1 Cleaning motorcycle 238 18 2 Checks and maintenance steps for winter operation 240 19 STORAGE 241 19 1 Storage 241 19 2 Preparing for use after storage 242 20 TROUBLESHOOTING 243 21 IMMOBILIZER BLINK CODE 246 22 ENGINE CONTROL BLINK CODE 248 23 TECHNICAL DATA 254 23 1 Motor 254 23 2 Motor...

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

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

Page 12: ... that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken Note Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken Warning Indicates a danger that will lead to environmental damage if the appropri...

Page 13: ...11 ...

Page 14: ...2 SAFETY ADVICE 12 2 4 Overview of labels B01298 10 ...

Page 15: ... label for the USA 4 Emission control information 5 Noise emission information 6 Chain tension information 7 Information on suspension setting 8 Information on locking of passenger seat 9 Information on fuel quality engine electronics mapping 600961 01 Information on putting into operation ...

Page 16: ...2 SAFETY ADVICE 14 M00734 01 Type label for Canada M00735 01 Type label for the USA ...

Page 17: ...2 SAFETY ADVICE 15 M00736 01 Emission control information M00737 01 Noise emission information ...

Page 18: ...2 SAFETY ADVICE 16 M00738 01 Chain tension information M00739 01 Information on suspension setting ...

Page 19: ... Inc If NHTSA receives multiple similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or KTM North America Inc To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 888 327 4236 or visit the ...

Page 20: ... QC J3V 6B7 Phone 450 441 4451 x 4250 www ktmcanada com 2 7 Operating noise warning This product should be checked for necessary repair or replacement parts if the motorcycle noise has increased significantly through use Otherwise the owner may become subject to penalties under the applicable ordinances 2 8 Consumer rights Warranty claims should be submitted to a KTM workshop If you are not satisf...

Page 21: ...emoval or puncturing of the main silencer baffles header pipes or any other components which conduct exhaust gases 2 Removal or puncturing of parts of the intake system 3 Lack of proper maintenance 4 Replacing moving part of the vehicle or parts of the exhaust or intake system with parts other than those specified by the manufac turer 2 10 Safe operation Danger Danger of accidents Danger arising f...

Page 22: ...nts an increased safety risk Wear protective clothing helmet boots gloves pants and jacket with protectors every time you ride the vehicle Always wear protective clothing that is in good condition and meets the legal requirements In the interest of your own safety KTM recommends that you only operate the vehicle while wearing protective clothing 2 12 Work rules Special tools are necessary for cert...

Page 23: ...al of an end of life motorcycle Your authorized KTM dealer will be glad to advise you 2 14 Owner s Manual It is important that you read this Owner s Manual carefully and completely before making your first trip The Owner s Manual contains use ful information and many tips on how to operate handle and maintain your motorcycle Only then will you find out how to customize the vehicle ideally for your...

Page 24: ... auxiliary substances such as fuel and lubricants as specified in the Owner s Manual 3 3 Spare parts accessories For your own safety only use spare parts and accessory products that are approved and or recommended by KTM and have them installed by an authorized KTM workshop KTM accepts no liability for other products and any resulting damage or loss Certain spare parts and accessory products are s...

Page 25: ...serve 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 be shown disassembled or may not be shown at all It is not always necessary to disassem ble the component to perform the activity in question Please follow the instructions in the text 3 6 Cust...

Page 26: ...4 VIEW OF VEHICLE 24 4 1 View of vehicle front left example B01301 10 ...

Page 27: ...Light switch p 33 2 Headlight flasher switch p 33 2 Turn signal switch p 34 2 Horn button p 32 3 Filler cap 4 Tool set p 110 5 Seat lock p 109 6 Oil dipstick 7 Side stand p 113 8 Shift lever p 111 9 Helmet lock p 113 10 Passenger footrests p 111 ...

Page 28: ...4 VIEW OF VEHICLE 26 4 2 View of vehicle rear right example B01302 10 ...

Page 29: ...teering lock p 35 5 Emergency OFF switch p 34 5 Electric starter button p 35 6 Hand brake lever p 31 7 Vehicle identification number type label p 28 8 Shock absorber rebound adjustment 9 Shock absorber compression adjustment 10 Foot brake lever p 112 11 Engine number p 29 12 Throttle grip p 32 13 Fork compression adjustment ...

Page 30: ... The type label for Canada is located on the frame on the left behind the steering head 5 2 Key number 402240 10 The key number Code number can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place Use the orange programming key to activate and deactivate the black ignition key Keep the orange programming key in a safe place it must only...

Page 31: ...SERIAL NUMBERS 29 5 3 Engine number 402296 10 The engine number is stamped on the right side of the engine 5 4 Fork part number 402295 10 The fork part number is stamped on the inner side of the fork stub ...

Page 32: ...mber 402298 10 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring towards the rear 5 6 Steering damper part number 402401 10 The steering damper part number is stamped on the top of the steering damper ...

Page 33: ...e clutch lever is fitted on the left side of the handlebar The clutch is hydraulic and self adjusting 6 2 Hand brake lever 100660 10 The hand brake lever is fitted on the right side of the handlebar The hand brake lever operates the front brake ...

Page 34: ...hrottle grip is fitted on the right side of the handlebar 6 4 Horn button 100661 12 The horn button is fitted on the left side of the handlebar Possible states Horn button in neutral position Horn button pressed The horn is operated in this position ...

Page 35: ...t are switched on High beam on The light switch is turned upwards In this position the low beam high beam and tail light are switched on 6 6 Headlight flasher switch 100662 10 The headlight flasher switch is fitted on the left side of the handlebar Possible states Headlight flasher switch in neutral position Headlight flasher switch pressed The headlight flasher switch high beam is oper ated in th...

Page 36: ...ed to the right The turn signal switch automatically returns to the central position after use To switch off the turn signal press the turn signal switch towards the switch housing 6 8 Emergency OFF switch 100664 10 The emergency OFF switch is installed on the right side of the handlebar Possible states Emergency OFF switch on This position is necessary for operation the ignition circuit is closed...

Page 37: ...iple clamp Info The ignition may only be switched on using a black ignition key Use the orange programming key to activate and deactivate the black ignition key Possible states Ignition OFF In this position the ignition circuit is interrupted a running engine stops and a non running engine cannot be started The black igni tion key can be removed Ignition ON In this position the ignition circuit is...

Page 38: ...400732 01 Park the vehicle Turn the handlebar all the way to the left Insert the key into the ignition handlebar lock press in and turn to the left Remove the key Steering is no longer possible 6 12 Unlocking the steering 400731 01 Insert the key into the ignition handlebar lock press in and turn to the right Remove the key The handlebar can now be moved again ...

Page 39: ...6 CONTROLS 37 6 13 Combination instrument 6 13 1 Overview 401121 10 1 Display p 40 2 Function buttons p 41 3 Indicator lamps p 42 4 Info display p 43 ...

Page 40: ... fitted on the handlebar front left The LAP button is fitted on the handlebar rear left MODE button Changes to the next item on the info display in ROAD mode and in RACE mode LAP button Changes to the next item on the info display in ROAD mode Clocks the lap times in RACE mode ...

Page 41: ...s switched on Test The segments of the tachometer and the gear display light up in and switch off in sequence The speed display counts from 0 to 300 and back The remaining display segments outside the info display light up briefly The KTM logo appears in the info display The display then changes to the last selected mode ...

Page 42: ...shows the engaged gear Info The engaged gear can also be displayed in the info display The speed is displayed in kilometers per hour KM H or in miles per hour MPH The time appears in segment Info The time must be reset after the battery was disconnected or the fuse was removed The coolant temperature is shown in degrees Celsius or Fahrenheit in segment The info display shows additional information...

Page 43: ...CONTROLS 41 6 13 5 Function buttons 400430 11 The button controls different functions The button controls different functions The button MODE switches between display modes or opens one of the setup menus ...

Page 44: ... The idle speed indicator lamp lights up green The transmission is shifted to idle The high beam indicator lamp lights up blue The high beam is switched on EFI warning lamp MIL lights up flashes red The OBD on board diagno sis has detected an emission or safety critical error The general warning lights up yellow An operating safety warning mes sage was detected This is also shown periodically in t...

Page 45: ...public roads Menu 2 is the RACE mode for riding on race tracks It allows riders to time laps themselves If the general warning lamp lights up the corresponding message is shown periodically in the info display Information repeat 45 s The information shown in the info display can be controlled with the function buttons ...

Page 46: ...ic components Never attach multiple ignition keys to a single key ring this may cause mutual interference and lead to problems A lost black ignition key must be deactivated to prevent unauthorized persons from operat ing the vehicle The second black ignition key is activated when the vehicle is shipped Two additional spare ignition keys key number on the KEYCODECARD can be ordered from an authoriz...

Page 47: ...lue Battery voltage 10 80 V 401125 01 SERVICE IN xxx KM MPH appears on the info display if the distance to the next service falls below the specified value Distance 500 km 310 mi 401166 01 HIGH TEMP appears on the info display if the coolant temperature rises above the specified value Coolant temperature 120 C 248 F ...

Page 48: ...01127 01 ICE appears on the info display if the external temperature falls below the specified value Temperature 3 C 37 F ICE disappears if the external temperature rises above the specified value Temperature 4 C 39 F ...

Page 49: ...47 ...

Page 50: ...6 CONTROLS 48 6 13 10 Overview of ROAD mode 401128 10 ...

Page 51: ... is on The motorcycle is being ridden ROAD mode Press the MODE button briefly and repeatedly until ODO Trip 1 Time 1 and Avs 1 appear in the info display ODO shows the total distance covered Trip 1 shows the distance covered since the last reset For example between two refueling stops Trip 1 is always running and counts up to 9999 9 Time 1 shows the journey time on the basis of Trip 1 and resumes ...

Page 52: ...1130 01 Condition Alternative 1 The ignition is on The motorcycle is stationary ROAD mode Alternative 2 The ignition is on The motorcycle is being ridden ROAD mode Press the MODE button briefly and repeatedly until ODO and Trip 2 appear in the info display ODO shows the total distance covered Trip 2 shows the distance covered since the last reset For example between two refueling stops Trip 2 is a...

Page 53: ...lay changes to the SET UP menu Press the MODE but ton for 3 5 sec onds The display of Trip 2 Time 2 and Avs 2 is reset Press the MODE but ton briefly Next display mode 6 13 13 Gear display menu ODO Trip 1 Gear 401131 01 Condition Alternative 1 The ignition is on The motorcycle is stationary ROAD mode Alternative 2 The ignition is on The motorcycle is being ridden ROAD mode Press the MODE button br...

Page 54: ...counts up to 9999 9 Gear shows the gear currently engaged Press the button No function Press the button No function Press the button and the button for 3 5 seconds The display changes to the SET UP menu Press the MODE but ton for 3 5 sec onds The display of Trip 1 Time 1 and Avs 1 is reset Press the MODE but ton briefly Next display mode ...

Page 55: ...el consumption Avg shows the average fuel consumption OutTemp shows the external temperature The external temperature can be switched on and off in the SET UP menu TripF shows the distance covered since the fuel reserve level was reached Info The TripF display only appears after you receive the fuel reserve level Press the button No function Press the button No function Press the button and the bu...

Page 56: ...ess the MODE button briefly and repeatedly until ENGINE MAP appears in the info dis play ENGINE MAP shows the active mapping for the engine electronics Press the button Changes the mapping Press the button Changes the mapping Press the button and the button for 3 5 seconds The display changes to the SET UP menu Press the MODE but ton for 3 5 sec onds Open and exit ENGINE MAP setting is saved Press...

Page 57: ...ly until DISTANCE TONext Service appears in the info display DISTANCE TO Next Service shows the distance before the next service is necessary Press the button No function Press the button No function Press the button and the button for 3 5 seconds The display changes to the SET UP menu Press the MODE but ton for 3 5 sec onds No function Press the MODE but ton briefly Next display mode ...

Page 58: ...6 CONTROLS 56 6 13 17 Overview of RACE mode 401142 10 ...

Page 59: ...143 01 Condition Alternative 1 The ignition is on The motorcycle is stationary RACE mode Alternative 2 The ignition is on The motorcycle is being ridden RACE mode Press the MODE button briefly and repeatedly until LAPSTOGO appears at the top left of the info display LAPSTOGO shows the number of remaining laps If an R appears after LAPSTOGO the stopwatch is running in the background If a P appears ...

Page 60: ... and the button for 3 5 seconds The display changes to the SET UP menu Press the MODE but ton for 3 5 sec onds All values in RACE mode are reset except RACEODO Press the MODE but ton briefly Next display mode 6 13 19 Maximum lap speed menu TOPSPEED 401144 01 Condition Alternative 1 The ignition is on The motorcycle is stationary RACE mode Alternative 2 The ignition is on The motorcycle is being ri...

Page 61: ...ximum speed difference between the last lap and the lap before Best shows the maximum speed difference between the last lap and the highest maximum speed If the last lap was the lap with the highest maximum speed the info display shows Best Best Press the button No function Press the button No function Press the button and the button for 3 5 seconds The display changes to the SET UP menu Press the...

Page 62: ...fo display LastLap shows the lap time of the last lap RaceTrip shows the distance covered since the last reset For example between two refuel ing stops RaceTrip is always running and counts up to 999 9 Gear shows the gear currently engaged Press the button No function Press the button No function Press the button and the button for 3 5 seconds The display changes to the SET UP menu Press the MODE ...

Page 63: ...el consumption Avg shows the average fuel consumption OutTemp shows the external temperature The external temperature can be switched on and off in the SET UP menu TripF shows the distance covered since the fuel reserve level was reached Info The TripF display only appears after you receive the fuel reserve level Press the button No function Press the button No function Press the button and the bu...

Page 64: ...ess the MODE button briefly and repeatedly until ENGINE MAP appears in the info dis play ENGINE MAP shows the active mapping for the engine electronics Press the button Changes the mapping Press the button Changes the mapping Press the button and the button for 3 5 seconds The display changes to the SET UP menu Press the MODE but ton for 3 5 sec onds Open and exit ENGINE MAP setting is saved Press...

Page 65: ...mber of the lap with the best lap time LapTime shows the time of the lap behind LAP Lap shows the difference to the lap before Lap shows the difference to the lap after Press the button The next lap is displayed Press the button The previous lap is displayed Press the button and the button for 3 5 seconds The display changes to the SET UP menu Press the MODE but ton for 3 5 sec onds All values in ...

Page 66: ...which the highest maximum speed was reached TopSpeed shows maximum speed of the lap behind LAP Lap shows the difference to the lap before Lap shows the difference to the lap after Press the button The next lap is displayed Press the button The previous lap is displayed Press the button and the button for 3 5 seconds The display changes to the SET UP menu Press the MODE but ton for 3 5 sec onds All...

Page 67: ...ered since the last reset For example between two refuel ing stops RaceTrip is always running and counts up to 999 9 MaxRPM shows the highest engine speed reached during the RaceTrip TopSpeed shows the highest speed reached during the RaceTrip Press the button No function Press the button No function Press the button and the button for 3 5 seconds The display changes to the SET UP menu Press the M...

Page 68: ...EMP OPTION TPMS BACK SET KM MILES SET C F SET FUEL CONS SET GAL US UK BACK SET UP CHANGE MODE SET CLOCK SETTINGS UNITS OPTIONS EXIT SETUP ODO Trip 1 ODO Trip 2 ODO Trip 1 Gear FUEL ENGINE MAP DISTANCE TO Next Service LAPSTOGO TOPSPEED LastLap RaceTrip Gear FUEL ENGINE MAP LAP BESTLAP LapTime LAP BESTLAP TopSpeed RACEODO 401152 01 ...

Page 69: ...6 CONTROLS 67 Settings in SET UP mode Mode menu CHANGE MODE Time menu SET CLOCK Settings menu SETTINGS Units menu UNITS Additional functions menu OPTIONS EXIT SETUP menu ...

Page 70: ...ning light the lap blank time of the LAP button the number of laps and the reset time of the fuel reserve display In the UNITS menu you can set the units for the speed or distance temperature and fuel consumption In the OPTIONS menu you can switch on and off the optional quick shifter the external temperature display and the optional tire pressure monitor Select EXIT SETUP to close the SET UP menu...

Page 71: ... on The motorcycle is stationary ROAD mode Alternative 2 The ignition is on The motorcycle is stationary RACE mode Press the button and the button for 3 5 seconds Press the MODE button briefly In the CHANGE MODE menu you can select between ROAD and RACE mode Press the button Changes the menu Press the button Changes the menu Press the button and the button for 3 5 seconds No function Press the MOD...

Page 72: ... the button for 3 5 seconds Press the button once until the symbol shows SET CLOCK in the info display Press the MODE button briefly You can set the clock in the SET CLOCK menu Press the button Increases the value Press the button Decreases the value Press the button and the button for 3 5 seconds No function Press the MODE but ton for 3 5 sec onds Open and exit SET CLOCK or change to the next val...

Page 73: ... menu you can activate the shift warning light In the LAP BLANK TIME menu you can set the lap blank time of the LAP button In the SET NUM LAPS menu you can set the number of laps to cover in RACE mode In the TRIP F RESET menu you can set the reaction time of the fuel reserve display to changes in the fuel level In the BACK menu you can switch back to the SET UP menu The symbol indicates which menu...

Page 74: ...cle is stationary ROAD mode Alternative 2 The ignition is on The motorcycle is stationary RACE mode Press the button and the button for 3 5 seconds Press the button twice until the symbol shows SETTINGS in the info display Press the MODE button briefly Press the MODE button briefly In the SHIFT RPMS menu you can activate the shift warning light Press the button Increases the value Press the button...

Page 75: ...ernative 2 The ignition is on The motorcycle is stationary RACE mode Press the button and the button for 3 5 seconds Press the button twice until the symbol shows SETTINGS in the info display Press the MODE button briefly Press the button once until the symbol shows LAP BLANK TIME in the info display Press the MODE button briefly In the LAP BLANK TIME menu you set the lap blank time of the LAP but...

Page 76: ...he motorcycle is stationary RACE mode Press the button and the button for 3 5 seconds Press the button twice until the symbol shows SETTINGS in the info display Press the MODE button briefly Press the button twice until the symbol shows SET NUM LAPS in the info display Press the MODE button briefly In the SET NUM LAPS menu you can set the number of laps to cover in RACE mode Press the button Incre...

Page 77: ...ion is on The motorcycle is stationary RACE mode Press the button and the button for 3 5 seconds Press the button twice until the symbol shows SETTINGS in the info display Press the MODE button briefly Press the button three times until the symbol shows TRIP F RESET in the info dis play Press the MODE button briefly In the TRIP F RESET menu you can set the reaction time of the fuel reserve display...

Page 78: ...6 CONTROLS 76 Press the button and the button for 3 5 seconds No function Press the MODE but ton for 3 5 sec onds Open and exit TRIP F RESET Press the MODE but ton briefly Open and exit TRIP F RESET ...

Page 79: ...for measuring speed and distance In the SET C F menu you can set the unit for the temperature display In the SET FUEL CONS menu you can set the unit liters of the fuel consumption In the SET GAL US UK menu you can set the unit gallons of the fuel consumption In the BACK menu you can switch back to the SET UP menu The symbol indicates which menu can be activated with the MODE button Press the butto...

Page 80: ...tionary RACE mode Press the button and the button for 3 5 seconds Press the button three times until the symbol shows UNITS in the info display Press the MODE button briefly Press the MODE button briefly In the SET KM MILES menu you can set the units for measuring speed and distance Press the button Changes the unit Press the button Changes the unit Press the button and the button for 3 5 seconds ...

Page 81: ...d the button for 3 5 seconds Press the button three times until the symbol shows UNITS in the info display Press the MODE button briefly Press the button once until the symbol shows SET C F in the info display Press the MODE button briefly In the SET C F menu you can set the unit for the temperature display Press the button Changes the unit Press the button Changes the unit Press the button and th...

Page 82: ...l shows UNITS in the info display Press the MODE button briefly Press the button twice until the symbol shows SET FUEL CONS in the info display Press the MODE button briefly In the SET FUEL CONS menu you can set the unit liters of the fuel consumption Press the button Changes the unit Press the button Changes the unit Press the button and the button for 3 5 seconds No function Press the MODE but t...

Page 83: ...lay Press the MODE button briefly Press the button three times until the symbol shows SET GAL US UK in the info dis play Press the MODE button briefly In the SET GAL US UK menu you can set the unit gallons of the fuel consumption Press the button Changes the unit Press the button Changes the unit Press the button and the button for 3 5 seconds No function Press the MODE but ton for 3 5 sec onds Op...

Page 84: ...OPTION QKSHIFT menu you can switch the optional quick shifter on off In the OPTION OUTTEMP menu you can switch the external temperature display on off In the OPTION TPMS menu you can switch the tire pressure check on off available as accessory In the BACK menu you can switch back to the SET UP menu The symbol indicates which menu can be activated with the MODE button Press the button The arrow mov...

Page 85: ... Press the button and the button for 3 5 seconds Press the button four times until the symbol shows OPTIONS in the info display Press the MODE button briefly Press the MODE button briefly In the OPTION QKSHIFT menu you can switch the optional quick shifter on off Press the button Switches quick shifter on and off Press the button Switches quick shifter on and off Press the button and the button fo...

Page 86: ...e button four times until the symbol shows OPTIONS in the info display Press the MODE button briefly Press the button once until the symbol shows OPTION OUTTEMP in the info display Press the MODE button briefly In the OPTION OUTTEMP menu you can switch the external temperature display on off Press the button Switches external temperature display on and off Press the button Switches external temper...

Page 87: ...until the symbol shows OPTIONS in the info display Press the MODE button briefly Warning Danger of accidents The tire pressure control system does not eliminate the necessity to check the tires before going on a ride To avoid false alarms the tire pressure values are evaluated over a period of several minutes Check the tire pressure before every ride Correct the tire pressure if the tire pressure ...

Page 88: ...it OPTION TPMS 6 13 44 Table of functions Display Press the button Press the button Press the button and the button for 3 5 seconds Press the MODE but ton for 3 5 sec onds Press the MODE but ton briefly Distance menu 1 ODO Trip 1 Time 1 Avs 1 No function No function The display changes to the SET UP menu The display of Trip 1 Time 1 and Avs 1 is reset Next display mode Distance menu 2 ODO Trip 2 T...

Page 89: ...play mode Remaining laps menu LAPSTOGO No function No function The display changes to the SET UP menu All values in RACE mode are reset except RACEODO Next display mode Maximum lap speed menu TOPSPEED No function No function The display changes to the SET UP menu The display of Last Lap Last and Best are set to 0 Next display mode Gear display menu Last Lap RaceTrip Gear No function No function Th...

Page 90: ...SET UP menu All values in RACE mode are reset except RACEODO Next display mode SET UP menu The arrow moves up The arrow moves down No function The menu in front of the arrow is selected The menu in front of the arrow is selected Mode menu CHANGE MODE Changes the menu Changes the menu No function Open and exit CHANGE MODE Open and exit CHANGE MODE Time menu SET CLOCK Increases the value Decreases t...

Page 91: ...unction Open and exit SET KM MILES Open and exit SET KM MILES Temperature display menu SET C F Changes the unit Changes the unit No function Open and exit SET C F Open and exit SET C F Fuel consumption menu liters SET FUEL CONS Changes the unit Changes the unit No function Open and exit SET FUEL CONS Open and exit SET FUEL CONS Fuel consumption menu gallons SET GAL US UK Changes the unit Changes t...

Page 92: ... menu activation Display The ignition is on The motor cycle is station ary ROAD mode The ignition is on The motor cycle is being ridden ROAD mode The ignition is on The motor cycle is station ary RACE mode The ignition is on The motor cycle is being ridden RACE mode The ignition is on The motor cycle is station ary The KM H unit is acti vated The ignition is on The motor cycle is station ary The M...

Page 93: ...on is on The motor cycle is station ary The KM H unit is acti vated The ignition is on The motor cycle is station ary The MPH unit is acti vated Menu can be activated Mapping menu ENGINE MAP Next service menu DISTANCE TO Next Service Remaining laps menu LAPS TOGO Maximum lap speed menu TOP SPEED Gear display menu LastLap RaceTrip Gear Fuel and external temperature menu FUEL Mapping menu ENGINE MAP...

Page 94: ...RACE mode The ignition is on The motor cycle is station ary The KM H unit is acti vated The ignition is on The motor cycle is station ary The MPH unit is acti vated Menu can be activated Total distance in Race mode menu RACEODO SET UP menu Mode menu CHANGE MODE Time menu SET CLOCK SETTINGS menu Shift warning lamp menu SHIFT RPMS LAP button blank time LAP BLANK TIME menu Number of laps menu SET NUM...

Page 95: ...n is on The motor cycle is station ary The KM H unit is acti vated The ignition is on The motor cycle is station ary The MPH unit is acti vated Menu can be activated Kilometers miles menu SET KM MILES Temperature display menu SET C F Fuel consumption menu liters SET FUEL CONS Fuel consumption menu gal lons SET GAL US UK Additional functions menu OPTIONS Quick shifter menu OPTION QKSHIFT External t...

Page 96: ...ode Press the MODE button briefly and repeatedly until ENGINE MAP appears in the info display Press the MODE button for 3 5 seconds Select the mapping with the button or the button Press the MODE button for 3 5 seconds The setting is stored 401148 01 Condition RACE mode Press the MODE button briefly and repeatedly until ENGINE MAP appears in the info display Press the MODE button for 3 5 seconds S...

Page 97: ...and repeatedly until LAP BESTLAP LapTime appears in the info display LAP01 appears on the left of the info display Press the button The next lap is displayed Press the button The previous lap is displayed Press the MODE button briefly Next display mode 6 13 48 Displaying maximum speed Condition The ignition is on The motorcycle is stationary RACE mode ...

Page 98: ...de Condition The ignition is on The motorcycle is stationary 400475 01 Press the button and the button for 3 5 seconds Press the MODE button briefly The mode set is shown in the info display Select ROAD mode or RACE mode with the button or the button Press the MODE button briefly The settings are stored and the display changes to the SET UP menu Press the button briefly and repeatedly until the sy...

Page 99: ... the button or the button Press the MODE button briefly The minutes are shown Set the minutes with the button or the button Press the MODE button briefly The settings are stored and the display changes to the SET UP menu Press the button briefly and repeatedly until the symbol shows EXIT SETUP in the info display Press the MODE button briefly 6 13 51 Adjusting the shift speed RPM1 2 Condition The ...

Page 100: ...s to flash Set the engine speed with the button or the button Press the MODE button briefly The engine speed after RPM2 flashes Info RPM2 is the engine speed above which the shift warning light lights up con stantly If RPM1 RPM2 the shift warning light lights up constantly when you reach the engine speed set Set the engine speed with the button or the button Press the MODE button briefly The setti...

Page 101: ... info display Press the MODE button briefly Press the button once until the symbol shows LAP BLANK TIME in the info display Press the MODE button briefly LAP BLANK T appears on the info display Info At delivery LAP BLANK T is set to 10 seconds Tip With LAP BLANK TIME function you can prevent the lap from being timed too short This may happen if you accidentally press the LAP button twice in a row ...

Page 102: ... button and the button for 3 5 seconds Press the button twice until the symbol shows SETTINGS in the info display Press the MODE button briefly Press the button twice until the symbol shows SET NUM LAPS in the info display Press the MODE button briefly TOTAL LAPS appears on the info display with the number of laps Info When delivered the number of TOTAL LAPS is set to 99 laps Set the number of lap...

Page 103: ...n for 3 5 seconds Press the button twice until the symbol shows SETTINGS in the info display Press the MODE button briefly Press the button three times until the symbol shows TRIP F RESET in the info dis play Press the MODE button briefly TRIPF RESET appears in the info display with the reaction time Info At delivery TRIPF RESET is set to 300 seconds Set the reaction time of the fuel reserve displ...

Page 104: ...y Press the MODE button briefly Press the button briefly and repeatedly until the symbol shows EXIT SETUP in the info display Press the MODE button briefly 6 13 55 Setting the kilometers miles SET KM MILES Info Making a country specific setting Condition The ignition is on The motorcycle is stationary ...

Page 105: ... unit with the button or the button Press the MODE button briefly The settings are stored and the display changes to the UNITS menu Press the button briefly and repeatedly until the symbol shows BACK in the info display Press the MODE button briefly Press the button briefly and repeatedly until the symbol shows EXIT SETUP in the info display Press the MODE button briefly 6 13 56 Setting the temper...

Page 106: ... Press the MODE button briefly The settings are stored and the display changes to the UNITS menu Press the button briefly and repeatedly until the symbol shows BACK in the info display Press the MODE button briefly Press the button briefly and repeatedly until the symbol shows EXIT SETUP in the info display Press the MODE button briefly 6 13 57 Setting the unit of fuel consumption liters SET FUEL ...

Page 107: ...button Press the MODE button briefly The settings are stored and the display changes to the UNITS menu Press the button briefly and repeatedly until the symbol shows BACK in the info display Press the MODE button briefly Press the button briefly and repeatedly until the symbol shows EXIT SETUP in the info display Press the MODE button briefly 6 13 58 Unit of fuel consumption gallons SET GAL US UK ...

Page 108: ...rs in the info display Select the unit with the button or the button Press the MODE button briefly The settings are stored and the display changes to the UNITS menu Press the button briefly and repeatedly until the symbol shows BACK in the info display Press the MODE button briefly Press the button briefly and repeatedly until the symbol shows EXIT SETUP in the info display Press the MODE button b...

Page 109: ...ored and the display changes to the OPTIONS menu Press the button briefly and repeatedly until the symbol shows BACK in the info display Press the MODE button briefly Press the button briefly and repeatedly until the symbol shows EXIT SETUP in the info display Press the MODE button briefly 6 14 Opening the filler cap Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open fl...

Page 110: ...iately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system B01306 10 Lift the cover of the filler cap and insert the ignition key in the lock Note Danger of damage Ignit...

Page 111: ...re that it is locked properly Change cloth ing that has been contaminated with fuel Immediately clean contaminated areas on the skin with soap and water Close the filler cap Push down the filler cap slightly until the lock closes Remove the ignition key and close the cover 6 16 Seat lock B01308 11 The seat lock is behind the seat It can be locked with the ignition key ...

Page 112: ...6 CONTROLS 110 6 17 Tool set 100670 10 The tool set is in the storage compartment under the seat 6 18 Supporting strap B01308 10 The supporting strap is provided for the passenger to hold on to ...

Page 113: ...ger footrests can be folded up and down Possible states Passenger footrests folded up For operation without a passenger Passenger footrests folded down For operation with a passenger 6 20 Shift lever B00558 10 The shift lever is mounted on the left of the engine ...

Page 114: ... positions can be seen in the picture The neutral or idle position is between the first and second gear 6 21 Foot brake lever B01309 10 The foot brake lever is in front of the right footrest The foot brake lever operates the rear brake ...

Page 115: ...n the side stand The safety start system is active Side stand folded in This position is mandatory for all journeys The safety start sys tem is inactive 6 23 Helmet lock B01311 01 The steel cable in the tool set can be used to lock a helmet to the vehicle to prevent it from being stolen Warning Danger of accidents Impairment of vehicle handling and vehicle operation if a hel met or helmet lock is ...

Page 116: ...erent tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Warning Danger...

Page 117: ...rake lever p 181 Adjust the foot brake lever p 154 Adjust the shift lever p 150 Get used to handling the vehicle on suitable terrain before making a longer trip Try also to ride as slowly as possible to get a better feeling for the motorcycle Hold the handlebars firmly with both hands and keep your feet on the footrests when riding Run the engine in p 115 7 2 Running the engine in Do not exceed th...

Page 118: ...ng characteristics at high speed Adapt your speed according to your payload If the motorcycle is loaded with luggage ride more slowly Maximum speed with luggage 130 km h 80 8 mph Warning Danger of accidents Destruction of luggage carrier system If the motorcycle is fitted with luggage cases note the manufacturer s specifications concerning the maximum payload Warning Danger of accidents Poor visib...

Page 119: ...ge make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu tion between the front and rear wheels Do not exceed the overall maximum permitted weight and the axle loads Guideline Maximum permissible total weight 380 kg 838 lb Maximum permissible front axle load 150 kg 331 lb Maximum permissible rear axle load 240 kg 529 lb ...

Page 120: ...ke fluid level p 183 Check the rear brake fluid level p 186 Check the front brake linings p 185 Check the rear brake linings p 189 Check the brake system Check the coolant level p 223 Check the chain for dirt p 172 Check the chain tension p 173 Check the tire condition p 198 Check the tire pressure p 200 Check the adjustment and smooth operation of all controls Check that the electrical equipment ...

Page 121: ... in an enclosed space without an effective exhaust extraction system Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic components and safety equipment may be damaged Never operate the vehicle with a discharged battery or without a battery Note Engine failure High engine speeds in cold engines have a negative effect on the service life ...

Page 122: ...rting the engine DO NOT apply the throttle If you apply the throttle during the starting procedure the engine management shuts off the injectors and the engine will not start Press the starter for a maximum of 5 seconds Wait for a least 5 seconds before trying again This motorcycle is equipped with a safety start system You can only start the engine if the transmission is in neutral or if the clut...

Page 123: ...key position Do not change the ignition key position during a journey Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle Make all adjustments when the vehicle is at a standstill Warning Risk of injury The passenger must be able to hold himself or herself properly on the passenger seat The passenger must hold on to the rider or supporting strap firmly and pl...

Page 124: ...l the tires have been run in Warning Danger of accidents Unstable handling characteristics Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational and with a full tank driver and passenger with protective clothing and helmet baggage Warning Danger of accidents Unstable handling characteristics due to slipped baggage Check the way your baggage...

Page 125: ... and open the throttle Info You can see the positions of the 6 forward gears in the figure The neutral or idle position is between the first and second gears First gear is used for starting off or for steep inclines After reaching maximum speed by fully opening the throttle turn the throttle back so it is open This will barely reduce the speed but fuel consumption will be considerably lower Accele...

Page 126: ... accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a dirty or wet brake system by riding and braking gently Warning Danger of accidents Reduced braking effect caused by spongy pressure point of front or rear brake Check the brake system and do not continue riding Your authorized KTM workshop will be pleased to help Warning Danger of accidents Failure of brake sys...

Page 127: ...two gears but do not race the engine You will require less braking force and the brakes will not overheat 8 6 Stopping parking Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons If you leave the vehicle lock the steering and remove the ignition key Warning Danger of burns Some veh...

Page 128: ...ou switch off the engine with the emergency OFF switch but the ignition remains switched on at the ignition lock power continues to flow to most power consumers and the battery is soon discharged Therefore always switch off the engine with the ignition key the emergency OFF switch is provided for emergency situations only Park the motorcycle on firm ground Swing the side stand to the front with yo...

Page 129: ...the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact ...

Page 130: ...he engine Adjust the mapping of the engine electronics for the fuel quality currently in use Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system B01312 10 Switch off the engine Open the filler cap p 107 Fill the fuel tank with fuel up to the lower edge of the fuel filler Total fuel tank...

Page 131: ... the oil screen p 228 Check the oil nozzle for the clutch lubrication Check the front brake linings p 185 Check the front brake discs p 181 Check the rear brake linings p 189 Check the rear brake disc p 182 Check that brake lines are undamaged and free of leaks Check the rear brake fluid level p 186 Check the free travel of the foot brake lever p 154 Check that the shock absorber and fork are leak...

Page 132: ...Change the secondary air system membranes Check all hoses e g fuel cooling bleeder drainage etc and sleeves for cracking leaks and incorrect rout ing Drain the drainage hose of the air filter box Check the antifreeze and coolant level Check the wiring harness of the throttle valve body for damage and correct routing Check cables for damage and kink free routing Check that the cables are undamaged ...

Page 133: ...uts for tightness Change the coolant Change the front brake fluid Change the rear brake fluid Check the headlight setting p 218 Check that the radiator fan is functioning properly Final check Check the vehicle for roadworthiness and take a test ride Read out the fault memory using the KTM diagnostics tool after a test ride Set the service interval display Make the service entry in the KTM Dealer n...

Page 134: ...up against the stop with force set the last discernible click as the last position These adjustments should be understood as a guideline and should always be the basis of your own personal chassis adaptation Do not change the adjustments at random or by more than 40 since otherwise the riding characteristics could deteriorate particularly at high speeds 10 2 Adjusting the compression damping of th...

Page 135: ...k type Guideline Compression damping Comfort 20 clicks Standard 15 clicks Sport 15 clicks Full payload 15 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping 10 3 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior An optimally adjusted rebound damping brakes the springing energy and enab...

Page 136: ...ebound damping Comfort 20 clicks Standard 20 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase suspension damping turn counterclockwise to reduce damping 10 4 Adjusting the spring preload of the fork Info Spring preload determines the initial fork position The best spring preload setting is achieved when it is set for the weight of the rider and that of any baggage and ...

Page 137: ...ou should also adjust the rebound damping when you alter the spring preload 10 5 Compression damping of the shock absorber The compression damping of the shock absorber is divided into two ranges high speed and low speed High speed and low speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed The high speed setting for example has an effect when riding over...

Page 138: ...ased to help Info The low speed setting can be seen during the slow to normal compression of the shock absorber 100686 10 Turn adjusting screw clockwise with a screwdriver up to the last perceptible click Info Do not loosen nut Turn counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Compression damping low speed Comfort 20 clicks Standard 20 clicks Sport 20...

Page 139: ...hop will be pleased to help Info The high speed setting can be seen during the fast compression of the shock absorber B00574 10 Turn adjusting screw clockwise all the way using a socket wrench Info Do not loosen nut Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort 3 turns Standard 2 5 turns Sport 1 5 turns Full p...

Page 140: ...ast perceptible click Turn counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 15 clicks Full payload 15 clicks Info Turn clockwise to increase suspension damping turn counterclockwise to reduce damping 10 9 Adjusting the spring preload of the shock absorber Warning Danger of accidents Modifications ...

Page 141: ...weight off the rear wheel and swingarm Info The spring preload can be adjusted correctly only if the rear wheel and the swingarm are fully relieved of weight Loosen screw by two turns 100690 01 Turn the adjusting ring counterclockwise with the wrench from the tool kit until the spring is no longer under tension Hook wrench 69012022000 Extension 60012060000 Turn the adjusting ring clockwise and ten...

Page 142: ...to the steering arising from acceleration on uneven ground at high speed or when the load is temporarily taken from the front wheel The steering damper is adjusted to suit the riding style and the road conditions For high speeds a setting with high damping can be chosen to make the best possible use of the steering damper function In slow tight bends intensive damping can negatively affect handlin...

Page 143: ...rclockwise towards as far as the last perceptible click Adjust the steering damper according to your riding style and the road conditions by turning the adjust screw clockwise towards Guideline Steering damper adjustment range 1 32 clicks Recommended range for use 1 20 clicks Standard 1 click Info Do not change the adjustment of the steering damper during the journey After adjusting the steering d...

Page 144: ...f the fork leg clamp and at the rear by the eccentric shaft The fork legs can be clamped at three positions in the triple clamp Upper triple clamp flush with upper edge of fork legs 0 mm 0 in Upper triple clamp flush with 1st ring of fork legs 2 5 mm 0 098 in Upper triple clamp flush with 2nd ring of fork legs stan dard 5 mm 0 2 in The infinitely variable frame height setting can be adjusted by tu...

Page 145: ...crew of the handlebar stub Info Loosen the screws far enough to prevent damage to the lacquer when the fork legs are moved Make the adjustments first on one fork leg and then on the other When the screws of both fork legs are loosened the vehicle sags toward the front 100695 01 Align the fork leg in the desired position by means of the fork rings Guideline Upper triple clamp flush with upper edge ...

Page 146: ... cle to become more stable but also more difficult to handle 100694 10 Tighten screw Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft Tighten screw Guideline Screw handlebar stub M8 20 Nm 14 8 lbf ft Repeat the adjustment on the other fork leg Info The vehicle level setting on both fork legs must be identical ...

Page 147: ...s ride behavior Following modifications ride slowly at first to get the feel of the new ride behavior 100696 10 Loosen screw 100697 10 Turn eccentric shaft to the desired position using the tool from the tool set Guideline Standard LOW Maximum adjustment range between HIGH LOW 180 Open end wrench SW 38 69012021000 Info The chassis height can be adjusted in both directions ...

Page 148: ...stem enables an individual setting of the footrest height and an individual adjustment of the controls The lower footrest position enables a more comfortable knee angle the upper footrest posi tion a sporting sitting position and more forward leaning freedom for use in racing 10 16 Adjusting the footrest position Info The footrest position must be identical on the left and the right ...

Page 149: ...th spacers and screws Guideline Standard Upper position Info The adjustable footrest bracket enables a more comfortable lower footrest posi tion or a sporting upper footrest position B00561 01 Mount and tighten the screws Guideline Screw front footrest bracket M8 25 Nm 18 4 lbf ft Loctite 243 ...

Page 150: ...10 TUNING THE CHASSIS 148 100702 01 Repeat adjustment work on the footrest bracket on the other side Adjust the shift lever p 150 Adjust the foot brake lever p 154 ...

Page 151: ...563 10 Remove the screw with the shift lever stub Position the shift lever stub with the screw in one of the holes according to the desired lever length Guideline Standard Central hole Tighten screw Guideline Screw shift lever stub M6 10 Nm 7 4 lbf ft Loctite 243 ...

Page 152: ...brake lever stub with the screw in one of the holes according to the desired lever length Guideline Standard Central hole Tighten the screw Guideline Bolt foot brake lever stub M6 10 Nm 7 4 lbf ft Loctite 243 10 19 Adjusting shift lever Info The footrest system offers many ways of adjusting the shift lever to your riding style and requirements ...

Page 153: ...move screws and take off the shift rod Loosen lock nuts Adjust the shift rod Guideline Shift rod adjustment range 114 153 mm 4 49 6 02 in Info Make the same adjustments on both sides At least 5 screw threads must be screwed into the seating ...

Page 154: ... lever lower drill hole shift shaft lower drill hole Shift power high short shift travel shift lever lower drill hole shift shaft upper drill hole Info The shift rod can be mounted both on the shift lever variably at an upper or lower position and on the reverse gear change of the shift shaft in two differ ent positions Mount and tighten the screws Guideline Screw shift rod M6 12 Nm 8 9 lbf ft Loc...

Page 155: ... or a low position of the shift lever Tighten the lock nuts of the shift rod Info After the counter nuts have been tightened the bearings of the shift shaft must be central and aligned identically to each other in order to ensure freedom of movement in the bearing shells Check the shift lever to ensure it is functioning properly and can move freely Guideline The moving parts of the shift lever mus...

Page 156: ...he hex nut is locked 100708 10 Check the foot brake lever setting Info Position of the foot brake lever may vary considerably depending on the set ting 10 21 Checking the free travel of the foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to over heating Adju...

Page 157: ...in the process If the free travel does not meet specifications Adjust the free travel 10 22 Handlebar height position 100755 10 Handlebar height By removing or inserting distance sleeve you can set the handlebar height to two differ ent positions Length distance sleeve 15 mm 0 59 in With distance sleeves the handlebar stub is positioned low for sports use Removing the distance sleeves gives a more...

Page 158: ...r position difference 6 5 Standard Position 10 23 Adjusting the handlebar height position Info The handlebar stub position must be identical on the left and right of the vehicle 100756 11 Adjusting the high position of the handlebar stubs Loosen screw Info Loosen the screw several turns to prevent damage to the fork paint when moving the handlebar stub Remove screw ...

Page 159: ...bove the triple clamp Mount and tighten screw Guideline Remaining frame bolts M5 5 Nm 3 7 lbf ft 100759 01 Tighten the screw Guideline Screw handlebar stub M8 20 Nm 14 8 lbf ft Repeat the adjustments on the other handlebar stub Move the handlebar to and fro over the entire steering range If the cables restrict the freedom of movement of the steering Correct the cable routing If a component restric...

Page 160: ...10 Remove screw with distance sleeve Carefully shift the handlebar stub by the length of the distance sleeve Watch out for the handlebar position difference Guideline Length distance sleeve 15 mm 0 59 in Handlebar position difference 6 5 Lay all cables between the upper triple clamp and the handlebar stub Position the distance sleeve Mount and tighten screw Guideline Remaining frame bolts M5 5 Nm ...

Page 161: ... the cable routing If a component restricts the freedom of movement of the steering or comes into contact with the trim Establish freedom of movement and reposition the component 600986 11 Adjusting the narrow position of the handlebar stubs Loosen screw Info Loosen the screw several turns to prevent damage to the fork paint when moving the handlebar stub Remove screw with distance sleeve Carefull...

Page 162: ...er the entire steering range If a component restricts the freedom of movement of the steering or comes into contact with the trim Establish freedom of movement and reposition the component 600986 10 Adjusting the wide position of the handlebar stubs Loosen screw Info Loosen the screw several turns to prevent damage to the fork paint when moving the handlebar stub Remove screw with distance sleeve ...

Page 163: ... stub Carefully move the handlebar to and fro over the entire steering range If a component restricts the freedom of movement of the steering or comes into contact with the trim Establish freedom of movement and reposition the component 10 24 Subframe position 400439 10 The subframe can be mounted in two different positions This enables the seat to be posi tioned at an ergonomic height Seat height...

Page 164: ...ications ride slowly at first to get the feel of the new ride behavior Preparatory work Remove the seat p 169 B01317 10 Main work Remove screws with the bushings B01318 10 Raising the seat position Remove screws with the washers on the left and right sides of the vehicle Push down on the subframe until the drilled holes of the frame are aligned with the holes at the bottom front of the subframe ...

Page 165: ...t B01318 11 Remove screws with the washers on the left and right sides of the vehicle Push up on the subframe until the drilled holes of the frame are aligned with the holes at the bottom rear of the subframe B01318 12 Tighten screws on the left and right sides of the vehicle Guideline Screw subframe M8 20 Nm 14 8 lbf ft Loctite 243 ...

Page 166: ...Mount the screws with the washer on the left and right sides of the vehicle but do not tighten yet B01318 14 Remove screws with the washers on the left and right sides of the vehicle Push up on the subframe until the drilled holes of the frame are aligned with the holes at the top front of the subframe B01319 01 Mount and tighten the screws with the washers on the left and right sides of the vehic...

Page 167: ...ne Screw subframe M8 20 Nm 14 8 lbf ft Loctite 243 Info Check the cable routing the lambda sensor cable should not be taut 305720 10 Mount rubber cover in the vacant threaded holes on both sides B01317 11 Position bushings Mount and tighten screws Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft ...

Page 168: ...10 TUNING THE CHASSIS 166 Finishing work Fit the seat p 170 ...

Page 169: ...t the rear Adapter 61029055120 Rear wheel stand 61029055400 Stand the motorcycle upright align the lifting gear to the link fork and the adapters and raise the motorcycle 11 2 Removing the rear of motorcycle from the lifting gear Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Secure the motorcycle against falling over Remove ...

Page 170: ...in work Move the handlebar to the straight ahead position Align the lifting gear at the front with the adapters to the fork legs Front wheel stand 61029055300 Info Always raise the rear of the motorcycle first Raise the motorcycle at the front 11 4 Taking the motorcycle off of the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a fi...

Page 171: ...in work Release bleeder screws Any excess pressure escapes from the interior of the fork Tighten the bleeder screws Info Perform this action on both fork legs 11 6 Removing the seat B01308 11 Insert the ignition key in the seat lock and turn it clockwise Raise the rear of the seat push it towards the rear and remove it upwards ...

Page 172: ... Warning Danger of accidents Impairment of vehicle handling and vehicle operation if a helmet or helmet lock is attached to the vehicle Do not use the helmet lock for holding a helmet or other objects during the journey Always remove the helmet lock before start ing out B01324 10 Remove the seat p 169 Position the steel cable from the tool kit with one loop on the lug Steel cable 60012015000 Guide...

Page 173: ...he passenger seat B01326 01 Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly After mounting the passenger seat check that it is locked correctly by pulling up Position the passenger seat in the space provided Press down the passenger seat until it clicks into place Finally check that the passenger seat is correctly mounted ...

Page 174: ...eir grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disp...

Page 175: ...accidents Danger caused by incorrect chain tension If the chain is too taut the components of the secondary power transmission chain engine sprocket rear sprocket bearings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme cases If the chain is too loose however i...

Page 176: ... Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain is too taut the components of the secondary power transmission chain engine sprocket rear sprocket 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 ex...

Page 177: ...nce marks The rear wheel is then correctly aligned Info The lower chain section must be taut Chain wear is not always even so you should repeat this measurement at differ ent chain positions Tighten nuts Make sure that the chain adjusters are on the adjusting screws Tighten nut Guideline Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Thread greased Info The wide adjustment range of the chain adj...

Page 178: ...hain rear sprocket and engine sprocket 100132 10 Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the power set Info The engine sprocket rear sprocket and chain should always be replaced together ...

Page 179: ...n Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance at the longest chain section 272 mm 10 71 in If distance is greater than the specified measurement Change the power set Info When the chain is replaced the rear sprocket and engine sprocket should also be changed A new chain wears out faster on old worn sprockets For safety rea...

Page 180: ...rivets of the chain are no longer visible at the lower edge of the open ing 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 chain sliding guard Guideline Screw chain sliding guard M5 5 Nm 3 7 lbf ft ...

Page 181: ...ndlebar Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 11 17 Checking fluid level of hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc Do not use brake flu...

Page 182: ...180 11 18 Correcting fluid level of hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc Do not use brake fluid Move the clutch fluid reservoir mounted on the handlebar to a horizontal position 100753 01 Remove screw cap with membrane Correct the fuel level Guideline The fluid level must be between the MIN and MAX markings Hydraulic fluid 15 p 270 Refit the sc...

Page 183: ...ning Danger of accidents Reduced braking efficiency due to worn brake disc s Change the worn brake disc s without delay Your authorized KTM workshop will be pleased to help 100135 10 Check the thickness of the brake disc in several places to see if it is within the speci fied wear tolerance Info Wear reduces the thickness of the brake discs in area of the brake discs Brake discs wear limit Front 4...

Page 184: ...ut delay Your authorized KTM workshop will be pleased to help 400480 10 Check the thickness of the brake disc in several places to see if it conforms to measure ment Info Wear reduces the thickness of the brake disc in area of the brake disc Brake disc wear limit Rear 4 5 mm 0 177 in If the brake disc thickness is less than the specified value Change the brake disc Check the brake disc for damage ...

Page 185: ...he front and rear brake according to the service schedule Your authorized KTM workshop will be pleased to help 100712 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Check the brake fluid level in the brake fluid reservoir If the brake fluid is below the MIN marking Add front brake fluid p 183 12 5 Adding brake fluid of front brake Warning Danger of accidents Fa...

Page 186: ...t and rear brake according to the service schedule Your authorized KTM workshop will be pleased to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not ...

Page 187: ...fluid immediately with water 12 6 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be pleased to help Note Danger of accidents Reduced braking efficiency caused by damaged brake discs If the brake linings are not changed in time the steel brake lining carriers...

Page 188: ...rake linings 12 7 Checking 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 linings Check the brake system and do not continue riding Your authorized KTM workshop will be pleased to help Warning Danger of accidents Reduced braking efficiency due to old ...

Page 189: ...em and do not continue riding Your authorized KTM workshop will be pleased to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warnin...

Page 190: ...rake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid is corrosive and will damage painted surfaces Use only clean brake fluid from a sealed container Preparatory work Check the rear brake linings p 189 B01337 10 Main work Stand the vehicle upright Remove screw cap with membrane Add brake fluid to the MAX level Brake fluid DOT 4 DOT 5 1 p...

Page 191: ...aged 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 brake linings regularly 100718 10 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings Check the b...

Page 192: ... Pull the brake calipers carefully back from the brake discs and hang them to one side Info Do not pull the hand brake lever when the brake calipers are removed C00335 10 Loosen screw by several rotations Release screws Press on screw to push the wheel spindle out of the axle clamp Remove screw Warning Danger of accidents Reduced braking efficiency due to damaged brake discs Always lay down the wh...

Page 193: ...13 2 Installing the front wheel C00336 11 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Replace the wheel bearing Clean and grease the shaft seal rings and mating surfaces of the spacers Long life grease p 272 ...

Page 194: ...and side when viewed in the direction of travel B00584 10 Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Clean screw and axle Lift the front wheel into the fork position it and insert the wheel spindle Mount and tighten screw Guideline Bolt front axle ...

Page 195: ...lever while it is actu ated The brake calipers align themselves Tighten screws on both brake calipers Guideline Screw front brake caliper M10x1 25 45 Nm 33 2 lbf ft Loctite 243 Release the fixation of the hand brake lever Take the motorcycle off of the front wheel stand p 168 Remove the rear of the motorcycle from the lifting gear p 167 B01403 10 Pull the front brake and compress the fork powerful...

Page 196: ...eel as far forward as possible and then remove the chain from the rear sprocket Info Cover the components to protect them against damage 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 Pull the rear wheel back and take it out of the swingarm Info Do not operate the foot brake lever when ...

Page 197: ...rear brake After installing the rear wheel always operate the foot brake until the pressure point is reached C00341 10 Main work Check the rear hub cush drive p 197 Remove bushing Clean and grease the mating surfaces of the bushing and the shaft seal rings Long life grease p 272 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Replace the wheel bearing Install th...

Page 198: ...pletely to the rear Position the rear wheel The brake caliper support and brake linings are correctly positioned C00344 01 Push the rear wheel as far forward as possible and place the chain on the rear sprocket Pull the rear wheel back and insert the wheel spindle ...

Page 199: ...x1 5 90 Nm 66 4 lbf ft Thread greased Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Finishing work Remove the rear of the motorcycle from the lifting gear p 167 Check the chain tension p 173 13 5 Checking rear hub cush drive Info The engine power is transmitted by the rear sprocket to the rear wheel through five sho...

Page 200: ... of the shock absorbers Finishing work Install the rear wheel p 195 Remove the rear of the motorcycle from the lifting gear p 167 Check the chain tension p 173 13 6 Checking the tire condition Warning Danger of accidents Uncontrollable vehicle handling in the event of a flat tire In the interest of safety replace damaged or worn tires immediately Your authorized KTM workshop will be pleased to hel...

Page 201: ...alternating angles The full grip levels are not achieved until the tires have been run in Info The type condition and air pressure of the tires all have a major impact on the handling of the motorcycle Worn tires have a negative effect on handling characteristics especially on wet surfaces 400602 10 Check the front and rear tires for cuts run in objects and other damage If the tires exhibit cuts r...

Page 202: ...fter five years If a tire is more than five years old Change the tires 13 7 Checking the tire pressure Info Low tire pressure leads to abnormal wear and overheating of the tire Correct tire pressure tool kit comfort and maximum tire service life 400695 01 Remove the dust cap Check the tire pressure when the tires are cold Tire air pressure solo Front 2 5 bar 36 psi Rear 2 5 bar 36 psi Tire air pre...

Page 203: ...13 WHEELS TIRES 201 Mount the dust cap Info The rubber seal in the dust cap prevents air from leaking out of the tire if the valve is defective ...

Page 204: ...Only charge in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic components and safety equipment may be damaged Never operate the vehicle with a discharge...

Page 205: ... 203 B01328 10 Main work Disconnect negative cable from the battery B01329 10 Remove the cover of the positive terminal Disconnect positive cable from the battery B01329 11 Remove screws Remove holder Lift out the battery ...

Page 206: ...he poles of the battery must face the rear of the vehicle Battery YTZ14S p 261 Position holder Mount and tighten screws Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft B01329 13 Position the positive cable and mount and tighten the screw Guideline Screw battery terminal M6 4 5 Nm 3 32 lbf ft Mount the positive terminal cover ...

Page 207: ... Avoid contact with battery acid and battery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Warning Environmental hazard The battery contains elements that are harmful to the environment Do not...

Page 208: ...ife If the charging current charging voltage and charging time are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and sulfate destroying the battery The ba...

Page 209: ...he battery Info Never remove lid Charge the battery to a maximum of 10 of the capacity specified on battery housing Switch off the battery charger after charging and disconnect from the battery Guideline The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the motorcycle is not in use 3 months Connect the negative cable with the battery Guideline...

Page 210: ...an be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never bypass or repair fuses Info The main fuse protects all power consumers of the vehicle The main fuse is under the seat Preparatory work Switch off all power consumers and the engine Remove the seat p 169 ...

Page 211: ...y main fuse Info A reserve fuse is located in the starter relay Install a new main fuse Fuse 58011109130 p 261 Tip Place the spare fuse in the starter relay so that it is available if needed Attach the protection covers Finishing work Fit the seat p 170 Set the clock with SET CLOCK p 96 ...

Page 212: ...verloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never bypass or repair fuses Info The fuse box containing the fuses of individual power consumers is located under the seat Preparatory work Switch off all power consumers and the engine Remove the seat p 169 B01331 10 Main work Open fuse box cover ...

Page 213: ...e plate lamp Fuse 3 10 A horn brake light Fuse 4 10 A radiator fan Fuse 5 10 A fuel pump Fuse 6 10 A ignition fuel injection Fuse 7 not used Fuse 8 10 A for auxiliary equipment permanent positive Fuse 9 10 A for auxiliary equipment accessories connected to the ignition switch Fuse 10 not used Fuse SPARE 10 A 15 A spare fuses Use spare fuses with the correct rating only Fuse 75011088010 p 261 Fuse ...

Page 214: ...educed brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off all power consumers and the engine 100742 10 Main work Fold up the combination instrument Pull the lug out of the rubber retainer Remove the rubber retainer ...

Page 215: ...Push off the retaining clamp on both sides squeeze and fold to the side Remove headlight bulb 700296 01 Position the new headlight bulb in the headlight housing Guideline Insert the headlight bulb so that lug is positioned in the cut out Low beam high beam H7 base PX26d p 261 Position the retaining clamp Plug in the connector ...

Page 216: ...01161 10 Position lug of the lamp cover in the notch Engage latch Check that the lighting is functioning properly 100742 10 Position the rubber holder Fold down the combination instrument Position the lug in the rubber retainer ...

Page 217: ...e lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off all power consumers and the engine B01332 10 Main work Remove screws Remove the cover 100746 10 Push latch in the direction of the arrow Remove the lamp cover ...

Page 218: ...th sides squeeze and fold to the side Remove headlight bulb Position the new headlight bulb in the headlight housing Guideline Insert the headlight bulb so that the lug is positioned in the cut out Low beam high beam H7 base PX26d p 261 Position the retaining clamp Plug in the connector ...

Page 219: ...r in the notch Engage the latch Check that the lighting is functioning properly B01332 10 Position the cover Info Check for correct positioning and freedom of movement of the brake lines Mount and tighten screws Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft ...

Page 220: ...distance in front of the wall and switch on the low beam Guideline Distance 5 m 16 ft The rider with luggage and passenger if applicable now mounts the motorcycle Check the headlight setting The light dark boundary must lie exactly on the lower mark when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applicable If the boundary between light and ...

Page 221: ... headlight range 14 10 Activating deactivating ignition key Info The orange programming key must only be used for activating and deactivating 401114 10 Loss of a black ignition key second black ignition key available If a black ignition key is lost or replaced the black ignition keys must be individually activated deactivated using the orange programming key This will also prevent the vehi cle fro...

Page 222: ...h The immobilizer indicator lamp lights up switches off briefly and switches on again Switch off the ignition by turning the black programming key to the position OFF Remove the black ignition key Insert the orange programming key in the ignition lock Switch on the ignition by turning the orange programming key to the ON position EFI warning lamp MIL lights up switches off and then starts to flash...

Page 223: ... the orange programming key to the ON position EFI warning lamp MIL lights up switches off and then starts to flash The immobilizer indicator lamp lights up switches off briefly and flashes according to the number of functioning black ignition keys including the orange programming key In this case once since all black ignition keys are deacti vated Switch off the ignition by turning the orange pro...

Page 224: ...ghts up switches off and then starts to flash The immobilizer indicator lamp lights up switches off briefly and switches on again Switch off the ignition by turning the black programming key to the position OFF Remove the black ignition key To activate further ignition keys repeat the last 4 steps with the respective ignition key Insert the orange programming key in the ignition lock Switch on the...

Page 225: ...e compensating tank When the temperature falls this surplus coolant is sucked back into the cooling system 401167 10 Cooling takes place by means of the air stream and a radiator fan which is controlled by a thermoswitch The lower the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect 15 2 Checking the coolant level Warning Danger of scalding During motorcycle oper...

Page 226: ...d coolant bleed the cooling system If the coolant in the compensating tank is not at the required level but the tank is not empty Check the cooling system for leaks Fill the cooling system compensating tank p 224 15 3 Filling cooling system compensating tank Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiato...

Page 227: ...ant Keep coolant out of reach of children Note Engine damage Impaired cooling efficiency due to air trapped in the cooling system After draining coolant and refilling the cooling system the motorcycle must be raised at the front according to the model type This is the only way of ensuring that the cooling system is filled without air bubbles Your authorized KTM workshop will be pleased to help B01...

Page 228: ...specifications Adjust the play in the throttle cable p 227 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and let it run idle Move the handleb...

Page 229: ...position Throttle position sensor circuit A check in zero position Info It is imperative to use the KTM diagnostics tool for this Push back protection cap Unscrew lock nut Set the play in the throttle cable by turning adjusting screw Guideline Throttle cable play 3 5 mm 0 12 0 2 in Tighten lock nut Mount the protection cap ...

Page 230: ...ent range Info After switching off the engine wait one minute before checking the level The engine oil level must be in the middle of the dip stick measurement range If the engine oil level is not at the specified level Add engine oil p 236 Replace the oil dipstick 17 2 Changing engine oil and filter cleaning oil screen 500281 01 Drain the engine oil and clean the oil screens p 229 Remove the oil ...

Page 231: ...e is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Drain the engine oil only when the engine is warm ...

Page 232: ...ff the left exhaust cover 100772 10 Stand the motorcycle on its side stand on a level surface Place a suitable container under the engine Remove the oil drain plugs with the magnets O rings and oil screens Remove the oil filter p 232 Completely drain the engine oil ...

Page 233: ...773 10 Thoroughly clean magnets and oil screens of the oil drain plugs 100772 11 Mount and tighten the oil drain plugs with the magnets O rings and oil screens Guideline Oil drain plug M20x1 5 20 Nm 14 8 lbf ft Install the oil filter p 234 ...

Page 234: ...screws Guideline Screw painted trim parts M5 3 5 Nm 2 58 lbf ft 17 4 Removing the oil filter Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water ...

Page 235: ...ld be disposed of as stipulated in applicable regulations Preparatory work Place a suitable container under the engine 100774 10 Main work Remove screws Take off oil filter cover with the O ring 100775 10 Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Clean the parts and the sealing area thoroughly ...

Page 236: ...ining engine screws M5 6 Nm 4 4 lbf ft 17 6 Filling up with engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the engine B01336 10 Main work The oil must be topped up in two steps Engine oil 3 60 l 3 8 qt External temperature 0 C 32 F Engine oil SAE 10W 50 p 268 External temperature 0 C 32 F Engine oil SAE 5W 40 p 269 Remove the dipstick and top up the e...

Page 237: ...t in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight Remove the dipstick and pour in the remaining engine oil Engine oil 2nd quantity 0 60 l 0 63 qt External temperature 0 C 32 F Engine oil SAE 1...

Page 238: ...system Start the engine and check that it is oil tight Finishing work Check the engine oil level p 228 17 7 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the engine Preparatory work Stand the motorcycle upright on a horizontal surface Check the engine oil level p 228 B01336 10 Main work Remove the dipstick and add engine oil Condition External...

Page 239: ...anger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight Finishing work Check the engine oil level p 228 ...

Page 240: ...leaners brake fluid etc should be disposed of as stipulated in applicable regulations Info To maintain the value and appearance of the motorcycle over a long period clean it regularly Avoid direct sunshine when cleaning the motorcycle 401061 01 Close off the exhaust system to keep water from entering Remove coarse dirt particles with a gentle spray of water Spray very dirty parts with a normal com...

Page 241: ...gine and brake system to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 172 Treat bare metal except for brake discs and the exhaust system with an anticorrosive Preserving materials for paints metal and rubber p 273 Treat all painted parts with a mild paint care product Special cleaner for glossy and matte paint finishes metal and plastic su...

Page 242: ...ean the brake system Info After EVERY trip on salted roads thoroughly clean the brake calipers and brake linings after they have cooled down while they are installed use cold water and dry them well After riding on salted roads thoroughly wash the motorcycle with cold water and dry it well Treat the engine swingarm and all other bright and zinc plated parts except for the brake discs with a wax ba...

Page 243: ...n 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 272 Fill up with fuel p 127 Clean the motorcycle p 238 Change the engine oil and filter clean the oil screen p 228 Check the coolant level p 223 Check the antifreeze Check the tire pressure p 200 Remove the battery p 202 Recharge the battery p 205 Guideline Storage temperature...

Page 244: ... running the engine for a short time only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 19 2 Preparing for use after storage 401059 01 Take the motorcycle off of the front wheel stand p 168 Remove the rear of the motorcycle from the lifting gear p 167 Install the battery p 204 Set the clock with SET CLOCK ...

Page 245: ...rol unit not activated Encode the EFI control unit Malfunction in CAN bus communica tion Read out the trouble code memory using the KTM diagnostics tool Combination instrument defective Check the combination instrument Engine cranks only if the clutch lever is pulled A gear is engaged Shift into neutral Safety start system defective Read out the trouble code memory using the KTM diagnostics tool E...

Page 246: ...olant in cooling system Check the cooling system for leaks Check the coolant level p 223 Cooling fins very dirty Clean cooling fins Kinked or damaged radiator hose Change the coolant hose Thermostat defective Check the thermostat Fuse 4 blown Change the fuses of individual power consumers p 210 Defect in radiator fan system Check the radiator fan system Air in cooling system Add coolant bleed the ...

Page 247: ...e 3 blown Change the fuses of individual power consumers p 210 Battery discharged Ignition not switched off when vehicle parked Recharge the battery p 205 Battery is not charged by the alternator Check charging voltage Combination instrument shows nothing in display Fuse 1 blown Change the fuses of individual power consumers p 210 Speedometer in combination instru ment doesn t work The wiring harn...

Page 248: ...rt 1 second pause 4x short Error level condition Malfunction in transponder of black ignition key Blink code of immobilizer indica tor lamp 15 Immobilizer indicator lamp flashes 1x short 1 second pause 5x short Error level condition Black ignition key inactive Blink code of immobilizer indica tor lamp 16 Immobilizer indicator lamp flashes 1x short 1 second pause 6x short Error level condition Malf...

Page 249: ...tion encryption query from EFI control unit to immobilizer control unit Blink code of immobilizer indica tor lamp 32 Immobilizer indicator lamp flashes 3x short 1 second pause 2x short Error level condition Malfunction in CAN bus communication Blink code of immobilizer indica tor lamp 60 Immobilizer indicator lamp flashes 6x short Error level condition E PROM malfunction ...

Page 250: ... lamp MIL flashes 7x short Error level condition Throttle position sensor circuit B input signal too low Throttle position sensor circuit B input signal too high Blink code EFI warning lamp MIL 09 EFI warning lamp MIL flashes 9x short Error level condition Manifold absolute pressure sensor cylinder 1 input signal too low Manifold absolute pressure sensor cylinder 1 input signal too high Blink code...

Page 251: ...l too low Intake air temperature sensor input signal too high Blink code EFI warning lamp MIL 14 EFI warning lamp MIL flashes 1x long 4x short Error level condition Ambient air pressure sensor input signal too low Ambient air pressure sensor input signal too high Blink code EFI warning lamp MIL 15 EFI warning lamp MIL flashes 1x long 5x short Error level condition Rollover sensor input signal too ...

Page 252: ...ode EFI warning lamp MIL 24 EFI warning lamp MIL flashes 2x long 4x short Error level condition Power supply circuit fault Blink code EFI warning lamp MIL 25 EFI warning lamp MIL flashes 2x long 5x short Error level condition Side stand switch circuit fault Blink code EFI warning lamp MIL 33 EFI warning lamp MIL flashes 3x long 3x short Error level condition Injector cylinder 1 circuit fault Blink...

Page 253: ...inder 2 circuit fault Blink code EFI warning lamp MIL 39 EFI warning lamp MIL flashes 3x long 9x short Error level condition Ignition coil 2 cylinder 1 circuit fault Blink code EFI warning lamp MIL 40 EFI warning lamp MIL flashes 4x long Error level condition Ignition coil 2 cylinder 2 circuit fault Blink code EFI warning lamp MIL 41 EFI warning lamp MIL flashes 4x long 1x short Error level condit...

Page 254: ...ater cylinder 2 sensor 1 short circuit to ground or open circuit Lambda sensor heater cylinder 2 sensor 1 input signal too high Blink code EFI warning lamp MIL 49 EFI warning lamp MIL flashes 4x long 9x short Error level condition Motor drive circuit A circuit fault Blink code EFI warning lamp MIL 50 EFI warning lamp MIL flashes 5x long Error level condition Motor drive circuit B circuit fault Bli...

Page 255: ...ing lamp MIL 69 EFI warning lamp MIL flashes 6x long 9x short Error level condition Manifold absolute pressure sensor cylinder 2 connection leaks Blink code EFI warning lamp MIL 81 EFI warning lamp MIL flashes 8x long 1x short Error level condition Immobilizer control unit circuit fault Blink code EFI warning lamp MIL 91 EFI warning lamp MIL flashes 9x long 1x short Error level condition CAN bus c...

Page 256: ...at 20 C 68 F 0 25 0 30 mm 0 0098 0 0118 in Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Crankshaft bearing Sleeve bearing Conrod bearing Sleeve bearing Piston pin bearing No bearing bushes DLC coated piston pins Piston Forged light alloy Piston ring 1 upper compression rectangular ring 1 lower compression ring 1 oil scraper ring Engine lubrication Dry sump lubrication system with three rotor ...

Page 257: ...ide spark plug NGK LMAR7A 9 Electrode gap spark plug 0 8 0 9 mm 0 031 0 035 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 500 1 600 rpm Cold start device Electric starter 23 2 Motor tightening torques Screw damping plate clutch cover EJOT ALtracs M6x10 10 Nm 7 4 lbf ft Loctite 243 Screw retaining bracket valve cover rear EJOT ALtracs M6x10 10 Nm 7 4 lbf ft Ho...

Page 258: ... Nm 8 9 lbf ft Screw coolant connection on cylinder head M6 10 Nm 7 4 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 holder M6 10 Nm 7 4 lbf ft Loctite 243 Screw locking lever M6 10 Nm 7 4 lbf ft Loctite 243 Screw oil pump cover M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift drum locating M6 10 Nm 7 4 l...

Page 259: ... 7 lbf ft Only applies when using Hex key bit 61229025000 Screw engine case M8 18 Nm 13 3 lbf ft Screw heat exchanger M8 15 Nm 11 1 lbf ft Screw timing chain guide rail M8 15 Nm 11 1 lbf ft Loctite 243 Screw timing chain tensioning rail M8 15 Nm 11 1 lbf ft Loctite 243 Stud exhaust flange M8 10 Nm 7 4 lbf ft Screw engine bearer M10 45 Nm 33 2 lbf ft Oil pressure sensor M10x1 10 Nm 7 4 lbf ft Plug ...

Page 260: ...m 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 engine sprocket M20x1 5 100 Nm 73 8 lbf ft Loctite 243 Oil drain plug M20x1 5 20 Nm 14 8 lbf ft Nut inner clutch hub M22x1 5 120 Nm 88 5 lbf ft Loctite 243 Plug timing chain tensioner M24x1 5 25 Nm 18 4 lbf ft Screw in alternator cover M24x1 5 8 Nm 5 9 lbf ft Nut primary gear M33LHx1 5 130 Nm 95 9 lbf ft...

Page 261: ...er unleaded ROZ 98 RON 98 PON 94 p 271 Fuel reserve approx 3 5 l 3 7 qt 23 4 Chassis Frame Lattice frame made of chromium molybdenum steel tubing powder coated Fork WP Suspension Up Side Down 4354 Shock absorber WP Suspension 4014 VP Suspension travel Front 120 mm 4 72 in Rear 120 mm 4 72 in Brake system Front Twin floating disc with radial mount 4 piston calipers Rear Single non floating disc wit...

Page 262: ...6 psi Rear 2 9 bar 42 psi Secondary drive 17 38 Chain 5 8 x 5 16 X ring Steering head angle 66 7 Wheelbase 1 425 mm 56 1 in Seat height unloaded Lower frame rear position 805 mm 31 69 in Upper frame rear position 825 mm 32 48 in Ground clearance unloaded 110 mm 4 33 in Weight without fuel approx 184 kg 406 lb Maximum permissible front axle load 150 kg 331 lb Maximum permissible rear axle load 240 ...

Page 263: ...gh beam H7 base PX26d 12 V 55 W Parking light LED Instrument lights and control lamps LED Turn signal LED Brake tail light LED License plate lamp W5W base W2 1x9 5d 12 V 5 W 23 6 Tires Front tires Rear tires 120 70 ZR 17 M C 58W TL Continental Conti SportAttack 2 190 55 ZR 17 M C 75W TL Continental Conti SportAttack 2 Additional information is available in the Service section under http www ktm co...

Page 264: ...omfort 20 clicks Standard 20 clicks Sport 10 clicks Full payload 10 clicks Spring preload Preload Adjuster Comfort 5 turns Standard 5 turns Sport 3 turns Full payload 3 turns Spring length with preload spacer s 405 mm 15 94 in Spring rate Medium standard 9 5 N mm 54 2 lb in Air chamber length 110 10 20 mm 4 33 0 39 0 79 in Fork length 728 mm 28 66 in Fork oil per fork leg 500 ml 16 9 fl oz Fork oi...

Page 265: ...andard 2 5 turns Sport 1 5 turns Full payload 1 5 turns Compression damping low speed Comfort 20 clicks Standard 20 clicks Sport 20 clicks Full payload 20 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 15 clicks Full payload 15 clicks Spring preload Comfort 9 mm 0 35 in Standard 9 mm 0 35 in Sport 9 mm 0 35 in Full payload 10 mm 0 39 in Spring rate ...

Page 266: ... fluid reservoir of rear brake M5 5 Nm 3 7 lbf ft Loctite 243 Screw brake line holder M5 5 Nm 3 7 lbf ft Screw chain guard M5 5 Nm 3 7 lbf ft Screw chain sliding guard M5 5 Nm 3 7 lbf ft Screw fuel level indicator M5 3 Nm 2 2 lbf ft Screw fuel tank guard M5x12 3 Nm 2 2 lbf ft Screw painted trim parts M5 3 5 Nm 2 58 lbf ft Screw steering damper fixing bracket M5 5 Nm 3 7 lbf ft Loctite 243 Bolt foo...

Page 267: ...deflector on shift shaft M6 18 Nm 13 3 lbf ft Loctite 243 Fork end pinch bolts M8 15 Nm 11 1 lbf ft Nut forked bracket on foot brake lever M8 30 Nm 22 1 lbf ft Loctite 243 Remaining chassis nuts M8 25 Nm 18 4 lbf ft Remaining chassis screws M8 25 Nm 18 4 lbf ft Screw for lifting gear support rear M8 18 Nm 13 3 lbf ft Screw of rear brake caliper M8 22 Nm 16 2 lbf ft Loctite 243 Screw bottom triple ...

Page 268: ...e clamp M8 10 Nm 7 4 lbf ft Loctite 243 Screw steering stem M8 20 Nm 14 8 lbf ft Screw subframe M8 20 Nm 14 8 lbf ft Loctite 243 Screw top triple clamp M8 17 Nm 12 5 lbf ft Remaining chassis nuts M10 45 Nm 33 2 lbf ft Remaining chassis screws M10 45 Nm 33 2 lbf ft Screw connecting lever shock absorber deflector M10 45 Nm 33 2 lbf ft Loctite 243 Screw engine bearer M10 45 Nm 33 2 lbf ft Screw shock...

Page 269: ...ivot M19x1 5 130 Nm 95 9 lbf ft Thread greased Screw seat lock M22x1 5 8 Nm 5 9 lbf ft Bolt front axle M25x1 5 45 Nm 33 2 lbf ft Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Thread greased Screw steering head M25x1 5 18 Nm 13 3 lbf ft ...

Page 270: ...RAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Only use high quality coolant with corrosion inhibitor for aluminum motors even in countries with high temperatures Using inferior antifreeze can result in corrosion and foaming Mixture ratio Antifreeze protection 25 45 C 13 49 F anti corrosion antifreeze distilled water Recommended supplier Motorex COOLANT M3 0 Engine oil SAE 10...

Page 271: ...classification JASO T903 MA p 274 SAE p 274 SAE 5W 40 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Synthetic engine oil Recommended supplier Motorex Power Synt 4T Fork oil SAE 5 Standard classification SAE p 274 SAE 5 Guideline Use only oils that comply with the specified standards see spec...

Page 272: ...x Hydraulic Fluid 75 Shock absorber fluid SAE 2 5 50180751S1 Standard classification SAE p 274 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding proper ties 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...

Page 273: ...BSTANCES 271 Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 Super unleaded ROZ 98 RON 98 PON 94 Standard classification DIN EN 228 ROZ 98 RON 98 PON 94 ...

Page 274: ... Chain Clean Chain lube for road use Guideline Recommended supplier Motorex Chainlube Road Fuel additive Recommended supplier Motorex Fuel Stabilizer Long life grease Recommended supplier Motorex Bike Grease 2000 Motorcycle cleaner Recommended supplier Motorex Moto Clean ...

Page 275: ...aints metal and rubber Recommended supplier Motorex Moto Protect Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommended supplier Motorex Quick Cleaner Universal oil spray Recommended supplier Motorex Joker 440 Synthetic ...

Page 276: ...rvice intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Stan dard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils...

Page 277: ...186 Brake linings front brake checking 185 rear brake checking 189 Brakes 124 Braking 124 C Capacity coolant 259 engine oil 234 258 259 fuel 128 259 Chain checking 176 checking for dirt 172 cleaning 172 Chain tension adjusting 174 checking 173 Clutch fluid level checking 179 fluid level correcting 180 Clutch lever 31 adjusting basic position 179 Combination instrument activation and test 39 additi...

Page 278: ...enu CHANGE MODE 69 88 92 next service menu DISTANCE TO Next Service 55 87 91 notes warnings 44 number of laps menu SET NUM LAPS 74 89 92 quick shifter menu OPTION QKSHIFT 83 89 93 remaining laps menu LAPSTOGO 57 87 91 SETTINGS menu 71 88 92 SET UP menu 68 88 92 shift warning lamp menu SHIFT RPMS 72 88 92 temperature display menu SET C F 79 89 93 time menu SET CLOCK 70 88 92 tire pressure monitor m...

Page 279: ...oving 190 Fuel consumption unit gallons SET GAL US UK setting 105 liters SET FUEL CONS setting 104 Fuel reserve display TRIP F RESET setting 101 Fuse individual power consumers changing 210 H Hand brake lever 31 basic position adjusting 181 Handlebar handlebar height 155 handlebar height adjusting 156 handlebar position 155 handlebar position adjusting 156 Headlight adjustment adjusting 218 checki...

Page 280: ...rcycle cleaning 238 raising the front with lifting gear 168 raising the rear with lifting gear 167 removing the front from the lifting gear 168 removing the rear from the lifting gear 167 N Number of laps SET NUM LAPS setting 100 O Oil filter changing 228 installing 234 removing 232 Oil screen cleaning 228 Oil screens cleaning 229 Operating substances 22 Owner s Manual 21 P Parking 125 Passenger f...

Page 281: ...ration 19 Seat fitting 170 removing 169 Seat lock 109 Service 22 Service schedule 129 131 SET C F temperature unit setting 103 SET CLOCK adjusting 96 Shift lever 111 setting 150 Shift lever stub adjusting 149 Shift speed RPM1 2 adjusting 97 Shifting 121 Shock absorber 132 compression damping general 135 compression damping high speed adjusting 137 compression damping low speed adjusting 136 reboun...

Page 282: ...4 motor tightening torques 255 shock absorber 263 tires 261 Throttle cable play adjusting 227 Throttle grip 32 Tire air pressure checking 200 Tire condition checking 198 Tool set 110 Transport 126 Troubleshooting 243 245 Turn signal switch 34 Type label 28 U Use definition 9 V Vehicle identification number 28 Vehicle level 142 front adjusting 143 rear adjusting 145 View of vehicle front left 24 re...

Page 283: ... 3213285en 3213285en 11 2014 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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KTM 1190 RC8 R EU/UK 2009, Owner'S Manual

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