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KTM 125 Duke 2017, Owner'S Manual

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KTM 125 Duke 2017 Owner'S Manual Download Page 101

12

SERVICE WORK ON THE CHASSIS

99

12.14

Checking the chain, rear sprocket, and engine sprocket

Preparatory work

–

Raise the motorcycle with the rear lifting gear. (

p. 88)

100132-10

Main work

–

Check the rear sprocket and engine sprocket for wear.
» If the rear sprocket and engine sprocket are worn:

–

Change the drivetrain kit.

Info

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

Summary of Contents for 125 Duke 2017

Page 1: ...OWNER S MANUAL 2017 125 Duke Art no 3213561en...

Page 2: ......

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

Page 4: ...O 9001 12 100 6061 According to the international quality management standard ISO 9001 KTM uses quality assurance processes that lead to the maximum possible quality of the products Issued by T V Mana...

Page 5: ...ERS 20 5 1 Chassis number 20 5 2 Type label 20 5 3 Engine number 21 5 4 Key number 21 6 CONTROLS 22 6 1 Clutch lever 22 6 2 Hand brake lever 22 6 3 Throttle grip 23 6 4 Switches on the left side of th...

Page 6: ...1 Trip 2 55 7 17 12 Warning 55 7 17 13 ABS 56 7 17 14 Favourites 57 7 17 15 Quick Selector 1 57 7 17 16 Quick Selector 2 58 7 17 17 Bluetooth 58 7 17 18 Shift Light 59 7 17 19 Setting the time and dat...

Page 7: ...the brake discs 105 13 3 Checking the brake fluid level of the front brake 106 13 4 Adding front brake fluid 107 13 5 Checking the front brake linings 109 13 6 Checking the free travel of foot brake...

Page 8: ...nd maintenance steps for winter operation 163 20 STORAGE 165 20 1 Storage 165 20 2 Preparing for use after storage 166 21 TROUBLESHOOTING 167 22 TECHNICAL DATA 170 22 1 Engine 170 22 2 Engine tighteni...

Page 9: ...th this symbol requires specialist knowledge and technical understanding In the interest of your own safety have these jobs performed by an authorized KTM workshop There your motorcycle will be optima...

Page 10: ...document are explained below Specific name Identifies a proprietary name Name Identifies a protected name Brand Identifies a brand available on the open market Underlined terms Refer to technical det...

Page 11: ...beyond the intended and defined use constitutes misuse Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respective use 2 3 Safety ad...

Page 12: ...Warning Indicates a danger that will lead to environmental damage if the appropriate measures are not taken 2 5 Tampering warning Tampering with the noise control system is prohibited Federal law pro...

Page 13: ...hem may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in a...

Page 14: ...new parts In some instances a thread locker e g Loctite is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them for da...

Page 15: ...then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it a...

Page 16: ...Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system Use operating and auxiliary substances such as fu...

Page 17: ...inspect or replace parts before the next scheduled service It is imperative that you adhere to the stipulated run in times and service intervals If you observe these exactly you will ensure a much lo...

Page 18: ...4 VIEW OF VEHICLE 16 4 1 View of vehicle front left example F00781 10...

Page 19: ...OF VEHICLE 17 1 Combination instrument 2 Rear mirror 3 Clutch lever p 22 4 Front rider s seat 5 Seat lock p 30 6 Passenger seat 7 Grab handles p 31 8 Shift lever p 32 9 Side stand p 34 10 Engine numbe...

Page 20: ...4 VIEW OF VEHICLE 18 4 2 View of vehicle rear right example F00782 10...

Page 21: ...h p 24 2 Turn signal switch p 25 2 Horn button p 25 3 Filler cap 4 Electric starter button p 26 4 Emergency OFF switch p 26 5 Hand brake lever p 22 6 Ignition steering lock p 27 7 Chassis number p 20...

Page 22: ...20 5 1 Chassis number 0 0 1 1 402408 10 The chassis number 1 is stamped on the right side of the steering head 5 2 Type label 0 0 1 1 402174 10 The type label 1 is on the right of the frame behind th...

Page 23: ...The engine number 1 is stamped on the left side of the engine under the engine sprocket 5 4 Key number 402245 10 The key number 1 can be found on the KEYCODECARD Info You need the key number to order...

Page 24: ...er F00717 10 The clutch lever 1 is fitted on the left side of the handlebar 6 2 Hand brake lever F00718 10 The hand brake lever 1 is fitted on the right side of the handlebar The front brake is engage...

Page 25: ...of the handlebar 6 4 Switches on the left side of the handlebar 6 4 1 Combination switch The combination switch is fitted on the left side of the handlebar F00720 10 Overview of the left combination s...

Page 26: ...the light switch to position B In this position the high beam and the tail light are switched on Headlight flasher Push the light switch into position C 6 4 3 Menu switch F00721 10 The menu switch is...

Page 27: ...pressed to the left The turn signal switch returns automatically to the central position after use Right turn signal on Turn signal switch pressed to the right The turn signal switch returns automati...

Page 28: ...circuit is interrupted a running engine stops and a non running engine cannot be started Emergency OFF switch on This position is required for operation the igni tion circuit is closed 6 5 2 Electric...

Page 29: ...ion the ignition circuit is closed and the engine can be started Steering locked LOCK In this position the ignition circuit is interrupted and the steering locked The ignition key can be removed 6 7 L...

Page 30: ...cap Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Swi...

Page 31: ...e of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow...

Page 32: ...y after closing Change your clothing in case of fuel spills on them Rinse the affected area immediately with plenty of water in the event of con tact with the skin Close the filler cap Push down the f...

Page 33: ...29 10 The tool set 1 is located under the passenger seat 6 13 Grab handles F00741 10 The grab handles 1 are used for moving the motorcycle around If you carry a passenger the passenger can hold onto t...

Page 34: ...footrests can be folded in and out Possible states Passenger footrests folded up For operation without a passenger Passenger footrests folded down For operation with a passenger 6 15 Shift lever 4019...

Page 35: ...an be seen in the photograph The neutral or idle position is between the first and second gears 6 16 Foot brake lever 402177 10 Foot brake lever 1 is located in front of the right footrest The foot br...

Page 36: ...e side stand must be folded up during motorcycle use Side stand is coupled with the safety start system see the riding instructions Possible states Side stand folded out The vehicle can be leaned on t...

Page 37: ...nction areas 1 indicator lamps p 38 Display 2 7 2 Activation and test F00876 01 Activation The combination instrument is activated when the ignition is switched on Info The brightness of the displays...

Page 38: ...rk color Info The light sensor in the combination instrument measures the brightness of the envi ronment and automatically switches the display to day or night mode The display is brightened darkened...

Page 39: ...relevance Yellow warning notes 1 indicate errors or information which requires prompt intervention or an adjustment to the riding style Red warning notes 2 indicate errors or information which require...

Page 40: ...7 COMBINATION INSTRUMENT 38 7 5 Indicator lamps F00900 01...

Page 41: ...ow The OBD has detected an emission or safety critical fault ABS indicator lamp lights up yellow Status or error messages relating to ABS The idle indicator lamp lights up green The transmission is in...

Page 42: ...7 COMBINATION INSTRUMENT 40 7 6 Display F00877 10...

Page 43: ...in the tachometer display 2 Gear display 3 Unit for the speed display 4 Speed p 44 5 Unit for the speedometer 6 ODO display p 44 7 Coolant temperature indicator p 45 8 Fuel level display p 45 9 Bluet...

Page 44: ...7 COMBINATION INSTRUMENT 42 7 7 Speed F00878 12 The speed 1 is measured in revolutions per minute...

Page 45: ...ift warning light can only be deactivated and the values for RPM1 and RPM2 can only be adjusted after this The shift warning light lights up red at RPM1and flashes red at RPM2 Info In sixth gear the s...

Page 46: ...1 is shown in kilometers per hour km h or in miles per hour mph 7 10 ODO display 402806 12 The total distance covered ODO is shown in area 1 of the display Info This value is retained even if the batt...

Page 47: ...ea 1 of the display The fuel level indicator consists of bars The more bars are lit the more fuel is in the fuel tank Info If the fuel level is getting low the last segment flashes red and the followi...

Page 48: ...n be configured in the Clock Date menu Info The time must be reset after the battery was disconnected or the fuse was removed 7 14 Favourites display 402811 01 Up to eight items of information are sho...

Page 49: ...ctor 1 Info The Quick Selector 1 can be configured in the Quick Selector 1 menu Any informa tion can be selected 7 16 Quick Selector 2 display F00802 01 When the menu is closed the Quick Selector 2 me...

Page 50: ...al F00804 01 Condition The motorcycle is stationary Function KTM MY RIDE activated optional Function Bluetooth activated Press the SET button when the menu is closed Press the UP or DOWN button until...

Page 51: ...Press the SET button to open the menu General information can be accessed in Info 7 17 3 Motorcycle F00804 03 Condition The motorcycle is stationary Press the SET button when the menu is closed Press...

Page 52: ...Favorites and quick selection can be configured in Settings 7 17 5 Preferences F00804 05 Condition The motorcycle is stationary Press the SET button when the menu is closed Press the UP or DOWN button...

Page 53: ...utton until Pairing is marked Press the SET button to pair a suitable cellphone with the combination instrument via Bluetooth Confirmation of the Passkey successfully completes the pairing Info When a...

Page 54: ...acts attention from traffic activity Always select headphone volume which is low enough for you to still clearly hear acoustic signals Press the UP or DOWN button until Audio is marked Press the SET b...

Page 55: ...ne volume which is too high distracts attention from traffic activity Always select headphone volume which is low enough for you to still clearly hear acoustic signals Press the SET button to accept a...

Page 56: ...tton until Info is marked Press the SET button to open the menu Press the UP or DOWN button until Trip 1 is marked Press the SET button to open the menu Trip 1 shows the distance since the last reset...

Page 57: ...and Trip Time2 Trip Time2 shows the journey time on the basis of Trip 2 and runs as soon as a speed signal is received Fuel Range indicates the possible distance you can cover with the fuel reserve Pr...

Page 58: ...ely the vehicle s approval for road use is invali dated Only operate the vehicle in closed off areas remote from public road traffic if the ABS is switched off completely Press the UP or DOWN button u...

Page 59: ...Up to eight items of information can be selected in the Favourites menu 7 17 15 Quick Selector 1 F00815 01 Condition The motorcycle is stationary Press the SET button when the menu is closed Press th...

Page 60: ...nd select it with the SET but ton Information can be selected in the Quick Selector 2 menu When the menu is closed the Quick Selector 2 menu is opened by pressing the DOWN but ton 7 17 17 Bluetooth F0...

Page 61: ...ton when the menu is closed Press the UP or DOWN button until Preferences is marked Press the SET button to open the menu Press the UP or DOWN button until Shift Light is marked Press the SET button t...

Page 62: ...Press the UP or DOWN button until Clock Date is marked Press the SET button to open the menu F00843 01 Setting the clock Press the UP or DOWN button until the time is marked Press the SET button The...

Page 63: ...month flashes and is underlined Press the UP or DOWN button until the current month is set Press the SET button The year flashes and is underlined Press the UP or DOWN button until the current year is...

Page 64: ...low beam is switched on per manently Note the legal regulations regarding the daytime running light Press the UP or DOWN button until DRL is marked Press the SET button to open the menu Activate the...

Page 65: ...ss the UP or DOWN button until Temp is marked Press the SET button to open the menu Activate the menu item using the UP or DOWN button Press the SET button to confirm the desired unit 7 17 23 Fuel Con...

Page 66: ...he SET button to open the menu Press the UP or DOWN button to activate the menu item and select it with the SET but ton The menu languages are US English UK English German Italian French and Spanish 7...

Page 67: ...DOWN button until Preferences is marked Press the SET button to open the menu Press the UP or DOWN button until Extra Functions is marked Press the SET button to open the menu Use the UP or DOWN butt...

Page 68: ...that is in good condition and meets the legal regulations Warning Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling characteristic Different tire tread...

Page 69: ...rols Get used to handling the motorcycle on a suitable piece of land before making a longer trip Try also to ride as slowly as possible to get a better feel for the vehicle Hold the handlebar firmly w...

Page 70: ...he manufacturer s instructions Warning Danger of accidents The luggage system will be damaged if it is overloaded Read the manufacturer information on maximum payload when mounting cases Warning Dange...

Page 71: ...f the vehicle and ensure even weight distribu tion between the front and rear wheels Do not exceed the overall maximum permitted weight and the axle loads Guideline Maximum permissible overall weight...

Page 72: ...level p 112 Check the front brake linings p 109 Check the brake linings of the rear brake p 116 Check the brake system function Check the coolant level p 146 Check for chain dirt accumulation p 94 Ch...

Page 73: ...of accidents Electronic components and safety devices will be damaged if the battery is discharged or missing Never operate the vehicle with a discharged battery or without a battery Note Engine damag...

Page 74: ...goes back out after starting off Press the electric starter button Info Do not press the electric starter button until the combination instrument func tion check is finished When starting DO NOT open...

Page 75: ...e the vehicle to get out of control Avoid abrupt load alterations and sudden braking actions Adapt your speed to the road conditions Warning Danger of accidents If you change down at high engine speed...

Page 76: ...danger as early as possible Warning Danger of accidents Cold tires have reduced road grip Ride the first miles carefully on every journey at moderate speed until the tires reach operating temperature...

Page 77: ...e clutch lever shift into the next gear release the clutch lever and open the throttle Info You can see the positions of the 6 forward gears in the figure The idle position is between the first and se...

Page 78: ...t a crossroads just pull the clutch lever and press the elec tric starter button You do not have to shift into neutral If the oil pressure warning lamp lights up during a trip stop immediately and swi...

Page 79: ...tance Take the longer stopping distance into account when carrying a passenger or luggage with you Warning Danger of accidents Salt on the roads impairs the brake system Brake carefully several times...

Page 80: ...peed Use the braking effect of the engine on long downhill stretches Change down one or two gears but do not over rev the engine In this way you have to brake far less and the brakes do not overheat 9...

Page 81: ...rials which are highly flammable or explosive Allow the vehicle to cool down before covering it Apply the brakes on the motorcycle Shift gear to neutral Switch off the ignition by turning the ignition...

Page 82: ...hazard Hot vehicle components pose a fire hazard and explosion risk Do not park the vehicle near to materials which are highly flammable or explosive Allow the vehicle to cool down before covering it...

Page 83: ...zard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse...

Page 84: ...ot allow fuel to enter the groundwater the soil or the sewage system F00732 10 Switch off the engine Open the filler cap p 28 Fill the fuel tank with fuel up to the lower edge 1 of the fuel filler Tot...

Page 85: ...t memory using the KTM diagnostics tool Check that the electrical system is functioning properly Change the engine oil and oil filter clean the oil screen p 156 Check the brake discs p 105 Check the f...

Page 86: ...Check the cables for damage and routing without sharp bends Check the valve clearance Check the valve clearance change the spark plugs Change the front brake fluid Change the rear brake fluid Check t...

Page 87: ...ck the swingarm bearing Check the wheel bearings Check the antifreeze Change the coolant Empty the drainage hoses Check all hoses e g fuel coolant bleeder drainage etc and sleeves for cracking leaks a...

Page 88: ...s the initial status of the spring operation on the shock absorber The best spring pretension setting is achieved when it is set for the weight of the rider and that of any baggage and a passenger thu...

Page 89: ...same adjustments on both sides At least five screw threads must be screwed into the seating Check adjusting angle B Guideline Adjusting angle B shift rod bell crank shift lever 90 Tighten nuts 1 Info...

Page 90: ...supports of the lifting gear Insert the adapter in the rear lifting gear Retaining adapter 61029955244 Lifting gear rear 69329955000 Stand the motorcycle upright align the lifting gear with the swing...

Page 91: ...vehicle on side stand 1 Remove bushings kit 12 3 Lifting the motorcycle with the front lifting gear Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and...

Page 92: ...nt 69329965000 Info Always raise the motorcycle at the rear first Raise the motorcycle at the front 12 4 Taking the motorcycle from the front lifting gear Note Danger of damage The parked vehicle can...

Page 93: ...reparatory work Raise the motorcycle with the rear lifting gear p 88 Lift the motorcycle with the front lifting gear p 89 E00735 10 Main work Push dust boots 1 of both fork legs downward Info The dust...

Page 94: ...bes of both fork legs Universal oil spray p 189 Press the dust boots back into their installation position Remove excess oil Finishing work Take the motorcycle from the front lifting gear p 90 Remove...

Page 95: ...ace 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 Fi...

Page 96: ...front rider s seat in area A and lower at the rear Finally check that the driver s seat is correctly mounted Finishing work Mount the passenger seat p 93 12 10 Checking for chain dirt accumulation 40...

Page 97: ...the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental dam...

Page 98: ...nger of accidents Incorrect chain tension damages components and results in accidents If the chain is tensioned too much the chain engine sprocket rear sprocket transmission and rear wheel bearings we...

Page 99: ...of the motorcycle from the lifting gear p 88 12 13 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents If the chain is tensione...

Page 100: ...and right chain adjusters 4 are in the same position relative to the reference marks A The rear wheel is then correctly aligned Info The upper part of the chain must be taut Chain wear is not always...

Page 101: ...ratory work Raise the motorcycle with the rear lifting gear p 88 100132 10 Main work Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the d...

Page 102: ...chain rollers in the lower chain section Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance B at the longest chain section 301 6 mm...

Page 103: ...screw 1 is visible from above Change the chain sliding guard Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the screw of the chain sliding guard Guidel...

Page 104: ...12 SERVICE WORK ON THE CHASSIS 102 12 15 Removing the front spoiler F00740 10 Remove screws 1 F00739 10 Remove screws 2 Take off the front spoiler...

Page 105: ...t spoiler F00740 10 Position the front spoiler Mount screws 1 but do not tighten yet F00739 10 Mount and tighten screws 2 Guideline Screw front spoiler rear M6x9 9 Nm 6 6 lbf ft Tighten screws 1 Guide...

Page 106: ...are parts on the brake system which have been approved and recom mended by KTM Only use tires wheels approved by KTM with the corresponding speed index Maintain the specified tire air pressure Service...

Page 107: ...must light up after the ignition is switched on and go out after starting off If it does not go out after starting off or if it lights up while riding this indi cates a fault in the ABS system In this...

Page 108: ...ange the rear brake disc Check the front and rear brake discs for damage cracking and deformation If the brake disc exhibits damage cracking or deformation Change the front brake disc Change the rear...

Page 109: ...a horizontal position Check the brake fluid level in viewer 1 If the brake fluid level is below the MINmarking Add front brake fluid p 107 13 4 Adding front brake fluid Warning Danger of accidents An...

Page 110: ...the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your auth...

Page 111: ...brake fluid immediately with water 13 5 Checking the front brake linings Warning Danger of accidents Worn out brake linings reduce the braking effect Ensure that worn out brake linings are replaced i...

Page 112: ...ings for damage and cracking If there is damage or cracking Change the front brake linings 13 6 Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the e...

Page 113: ...n If the free travel does not meet specifications Adjust the free travel of the foot brake lever p 111 Reconnect spring 1 13 7 Adjusting the free travel of the foot brake lever Warning Danger of accid...

Page 114: ...w 3 and tighten nut 2 Attach spring 1 13 8 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid leve...

Page 115: ...brake fluid level of the brake fluid reservoir If the fluid level reaches the MIN marking 1 Add rear brake fluid p 113 13 9 Adding rear brake fluid Warning Danger of accidents An insufficient brake fl...

Page 116: ...th the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake...

Page 117: ...w cap 2 with membrane 3 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 185 Mount screw cap with membrane Info Clean up overflowed or spilled brake fluid immediately with water H01142 10 Condit...

Page 118: ...braking effect If the brake linings are not changed in time the brake lining carriers grind against the brake disc As a consequence the braking effect is greatly reduced and the brake discs are destr...

Page 119: ...wheel speed sensor 3 out of the hole Loosen screw 4 by several rotations Loosen screws 5 Press on screw 4 to push the wheel spindle out of the axle clamp Remove screw 4 Warning Danger of accidents Re...

Page 120: ...p the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary F00755 10 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change th...

Page 121: ...n the drill hole Mount and tighten screw 4 Guideline Screw wheel speed sensor holder M6 8 Nm 5 9 lbf ft Mount and tighten screws 5 with the washers Guideline Screw front fender M6 7 Nm 5 2 lbf ft Oper...

Page 122: ...14 WHEELS TIRES 120 Guideline Screw fork stub M8 15 Nm 11 1 lbf ft 14 3 Removing the rear wheel Preparatory work Raise the motorcycle with the rear lifting gear p 88 F00776 10 Main work Remove screw 1...

Page 123: ...d to the side Warning Danger of accidents Reduced braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not dam aged Pull the rear wheel back an...

Page 124: ...earing Remove the spacers Clean and grease shaft seal rings 1 and contact surfaces A of the spacers Long life grease p 188 Clean the thread of the wheel spindle and axle nut Clean and grease wheel spi...

Page 125: ...h the screws and tighten nut 2 Guideline In order for the rear wheel to be correctly aligned the markings on the left and right chain adjusters must be in the same position relative to reference marki...

Page 126: ...wear out during operation If the rubber dampers are not changed in time the rear sprocket carrier and the rear hub will be damaged Preparatory work Raise the motorcycle with the rear lifting gear p 8...

Page 127: ...wheel p 121 Remove the rear of the motorcycle from the lifting gear p 88 Check the chain tension p 96 14 6 Checking the tire condition Warning Danger of accidents If a tire bursts while riding the veh...

Page 128: ...act on the handling characteristics 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...

Page 129: ...f the actual state of wear If the tires are more than 5 years old Change the tires 14 7 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire Cor...

Page 130: ...14 WHEELS TIRES 128 Correct the tire air pressure Mount the dust cap...

Page 131: ...ing lights using the menu before going on a ride or when stopped so that the low beam is switched on permanently Note the legal regulations regarding the daytime running light The daytime running ligh...

Page 132: ...gases Keep sparks or open flames away from the battery Only charge batteries in well ventilated rooms Rinse the affected area immediately with plenty of water in the event of contact with the skin Rin...

Page 133: ...motorcycle with a discharged battery or without a battery In both cases electrical components and safety devices can be damaged The vehi cle will therefore no longer be roadworthy 15 3 Installing the...

Page 134: ...ous chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and safety glasses Avoid contact with battery acid and battery gases Keep sparks or open flames away fr...

Page 135: ...ging current charging voltage or charging time is exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeated...

Page 136: ...emove lid 1 Charge the battery with a maximum of 10 of the capacity specified on battery housing 2 Switch off the battery charger after charging and disconnect from the battery Guideline The charge cu...

Page 137: ...fuse which protects the ABS control unit is located in the fuse box Preparatory work Switch off all power consumers and the engine Remove the passenger seat p 92 F00758 10 To change the fuse of the A...

Page 138: ...rical system Only use fuses with the required ampere value Do not bypass or repair fuses Use spare fuses with the correct rating only Fuse 90111088025 p 175 Tip Replace spare fuse 4 in the fuse box so...

Page 139: ...ment Fuse 3 10 A power relay Fuse 4 15 A ignition coil fuel pump start auxiliary relay horn Fuse 5 10 A radiator fan Fuse 6 15 A brake light turn signal high beam low beam parking light tail light lic...

Page 140: ...ot bypass or repair fuses Use spare fuses with the correct rating only Fuse 75011088010 p 175 Fuse 75011088015 p 175 Fuse 75011088030 p 175 Tip Replace the spare fuse in the fuse box so that it is ava...

Page 141: ...e wall at a distance A from the wall and switch on the low beam Guideline Distance A 5 m 16 ft The rider with luggage and passenger if applicable now mounts the motorcycle Check the headlight setting...

Page 142: ...adlight range If you have a payload you may have to correct the headlight range Screw 1 also secures the headlight Ensure the screw is always screwed in far enough 400726 11 Set the headlight to marki...

Page 143: ...or 1 is located under the passenger seat 15 10 USB diagnostics plug H01907 10 The USB diagnostics plug 1 is located under the combination instrument Info The USB diagnostics plug is intended for diagn...

Page 144: ...ming of the cooling system is regulated by a valve in radiator cap 2 Heat expansion causes excess coolant to flow into compensating tank 3 When the temperature falls this surplus coolant is sucked bac...

Page 145: ...EM 143 H01904 10 The coolant is cooled by the air stream and a radiator fan 4 which is controlled by a ther moswitch The lower the speed the less the cooling effect Dirty cooling fins also reduce the...

Page 146: ...components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of...

Page 147: ...be between the two markings If the coolant level does not match the specified value Correct the coolant level Coolant p 185 Mount the cap of the compensating tank F00763 10 Remove radiator cap 2 Check...

Page 148: ...n before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning...

Page 149: ...specified value Correct the coolant level Coolant p 185 F00763 10 Remove radiator cap 2 and check the coolant level in the radiator The radiator must be filled completely If the coolant level does not...

Page 150: ...In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow...

Page 151: ...bleeding the cooling system Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes...

Page 152: ...and tighten the bleeder screw immediately Coolant p 185 Completely fill the radiator with coolant Mount the radiator cap Rest the vehicle on the side stand Danger Danger of poisoning Exhaust gases ar...

Page 153: ...d allow it to cool down When the engine is cool check the coolant level in the radiator and if necessary add coolant Remove cap 3 of the compensating tank and top up the coolant level to the upper mar...

Page 154: ...ot meet the specified value Adjust the play in the throttle cable p 153 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure th...

Page 155: ...turning adjusting screw 3 Guideline Throttle cable play 3 5 mm 0 12 0 2 in Tighten lock nut 2 Slide on sleeve 1 17 3 Checking the clutch lever play Note Clutch damage If there is no play on the clutch...

Page 156: ...is perceptible and determine the play in the clutch lever A Clutch lever play A 1 3 mm 0 04 0 12 in If the clutch lever play does not meet the specified value Adjust play in the clutch lever p 155 Mo...

Page 157: ...lever F00768 10 Move the handlebar to the straight ahead position Push back sleeve 1 Loosen lock nut 2 Adjust the play in the clutch level A by turning adjusting screw 3 Guideline Clutch lever play A...

Page 158: ...checking the level The engine oil must be between the markings A and B If the engine oil is below the marking A Add engine oil p 159 If the engine oil is above the marking B Correct the engine oil lev...

Page 159: ...e engine is warm Preparatory work Remove the front spoiler p 102 Stand the motorcycle on its side stand on a horizontal surface F00769 10 Main work Place a suitable container under the engine Remove o...

Page 160: ...pletely drain the engine oil Thoroughly clean the parts and sealing surface F00771 10 Insert new oil filter 5 Lubricate the O ring of the oil filter cover Mount oil filter cover 6 Mount and tighten sc...

Page 161: ...O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an eff...

Page 162: ...ngine oils We recommended changing the engine oil when necessary Install and tighten the oil filler plug with O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in...

Page 163: ...ctly on to electrical components connectors throttle cables or bearings Maintain a minimum distance between the nozzle of the pressure cleaner and the component Minimum clearance 60 cm 23 6 in Warning...

Page 164: ...enhance the corrosive effects of salt After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the closure of the exhaust system Warning Danger of accidents Moistur...

Page 165: ...air the material quality Treat all plastic parts and powder coated parts with a mild cleaning and care product Special cleaner for glossy and matte paint finishes metal and plastic surfaces p 189 Oil...

Page 166: ...e parts are cooled down and while they are installed 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...

Page 167: ...g for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 188 Refuel p 81 Clean the motorcycle p 161 Change the engine oil and oil filter clean the oil screen p...

Page 168: ...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 20 2 Preparing for use after sto...

Page 169: ...Carry out the start procedure p 71 Fault in fuel injection system Read out the fault memory using the KTM diag nostics tool Engine has too little power Air filter is very dirty Change the air filter F...

Page 170: ...sumption Engine vent hose bent Route the vent hose without bends or change it if necessary Engine oil level too high Check the engine oil level p 156 Engine oil too thin low viscosity Change the engin...

Page 171: ...ent shows nothing on the display Fuse 2 is blown Change the fuses of individual power consumers p 136 Speedometer in combination instru ment not functioning Speedometer wiring harness is dam aged or p...

Page 172: ...nce intake cold 0 08 0 12 mm 0 0031 0 0047 in Valve clearance exhaust cold 0 13 0 17 mm 0 0051 0 0067 in Crankshaft bearing Two ball bearings Conrod bearing Sleeve bearing Pistons Cast light alloy Pis...

Page 173: ...n Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 450 1 550 rpm Starting aid Electric starter 22 2 Engine tightening torques Oil nozzle M5 6 Nm 4 4 lbf ft Loctite 243...

Page 174: ...octite 243 Screw locking lever M6 12 Nm 8 9 lbf ft Loctite 243 Screw oil filter cover M6 12 Nm 8 9 lbf ft Screw oil pump M6 12 Nm 8 9 lbf ft Loctite 243 Screw retaining bracket shaft seal ring clutch...

Page 175: ...0 Nm 51 6 lbf ft Loctite 243 Water temperature sensor M10 14 Nm 10 3 lbf ft Screw plug cam lever axis M10x1 10 Nm 7 4 lbf ft Spark plug M12 15 Nm 11 1 lbf ft Nut inner clutch hub M14LH 60 Nm 44 3 lbf...

Page 176: ...ed Fork WP Suspension Shock absorber WP Suspension Brake system Front Disc brake with four pot brake caliper Rear Disc brake with single piston brake caliper floating Suspension travel Front 142 mm 5...

Page 177: ...nce unloaded 175 mm 6 89 in Dry weight 139 kg 306 lb Maximum permissible front axle load 127 kg 280 lb Maximum permissible rear axle load 228 kg 503 lb Maximum permissible overall weight 355 kg 783 lb...

Page 178: ...150 60 R 17 M C 66H TL Michelin Pilot Street Radial The tires specified represent one of the possible series production tires Additional information is available in the Service section under http www...

Page 179: ...k rear brake M5 9 Nm 6 6 lbf ft Screw fuel tank cover M5 4 Nm 3 lbf ft Screw outer clutch cable guide M5 5 Nm 3 7 lbf ft Screw side stand switch M5 5 Nm 3 7 lbf ft Loctite 243 Screw tail light M5 5 Nm...

Page 180: ...4 4 lbf ft Screw front spoiler front M6x13 9 Nm 6 6 lbf ft Screw front spoiler rear M6x9 9 Nm 6 6 lbf ft Screw fuel pump M6 10 Nm 7 4 lbf ft Screw headlight M6 8 Nm 5 9 lbf ft Screw ignition coil M6 8...

Page 181: ...fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 30 Nm 22 1 lbf ft Loctite 204 Screw front brake disc M8 30 Nm 22 1 lbf ft Loctite 243 Screw front seat fixing M8 20 Nm 14 8 lbf ft Screw fro...

Page 182: ...Loctite 243 Nut mirror right M10LHx1 25 16 Nm 11 8 lbf ft Screw combination instrument bracket M10x1 25 21 Nm 15 5 lbf ft Screw front footrest bracket M10x1 25 44 Nm 32 5 lbf ft Screw front footrest...

Page 183: ...22 TECHNICAL DATA 181 Nut steering head M30x1 1st stage 45 Nm 33 2 lbf ft 2nd stage loosen counter clockwise 2 turns 3rd stage 5 Nm 3 7 lbf ft...

Page 184: ...idelines The full text of the EU Decla ration of Conformity is available at the following Internet address Certification website http www ktm com ktm race on system KTM AGhereby declares that the LC8...

Page 185: ...2564N KTM RACE ON system Active Key FCC ID VFZKLGKZADI01 IC 22239 KLGKZADI01 KTM RACE ON system Main Unit FCC ID VFZKLGMZADI01 IC 22239 KLGMZADI01 LC8 DASHBOARD FCC ID 2AKP9 LC8CLUSTER1 IC 22273 LC8C...

Page 186: ...hey are not installed and operated in accordance with the instructions they may cause harmful interference to radio reception However there is no guarantee that interference will not occur in certain...

Page 187: ...additive for aluminum motors Low grade and unsuitable antifreeze causes corrosion deposits and frothing Do not use pure water as only coolant is able to meet the requirements needed in terms of corro...

Page 188: ...e Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Partially synthetic engine oil Recommended supplier Mo...

Page 189: ...the corresponding proper ties Recommended supplier Motorex Racing Fork Oil Super unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super...

Page 190: ...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...

Page 191: ...ex Moto Polish Shine Preserving materials for paints metal and rubber Recommended supplier Motorex Moto Protect Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommend...

Page 192: ...ong service intervals are demanded for automobile engines the focus for motorcycle engines is on high performance at high engine speeds In most motorcycle engines the transmission and the clutch are l...

Page 193: ...me Running Light Light which enhances the visibility of the vehicle during the day but is not focused and in contrast to low beam does not illuminate the road surface KTM MY RIDE System for wireless c...

Page 194: ...28 LIST OF ABBREVIATIONS 192 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 195: ...p lights up yellow The OBD has detected an emission or safety critical fault ABS indicator lamp lights up yellow Status or error messages relating to ABS The general warning lamp lights up yellow An o...

Page 196: ...g 113 Brake fluid level front brake checking 106 rear brake checking 112 Brake linings front brake checking 109 rear brake checking 116 Brakes 76 C Capacity coolant 173 engine oil 159 173 fuel 82 174...

Page 197: ...1 display 47 Quick Selector 2 58 Quick Selector 2 display 47 Service 64 Settings 50 shift warning light 43 speed 42 44 telephony 53 Temp 63 time 46 Trip 1 54 Trip 2 55 Warning 55 warning notes 37 Comb...

Page 198: ...legs dust boots cleaning 91 Front rider s seat mounting 94 removing 93 Front spoiler installing 103 removing 102 Front wheel installing 118 removing 117 Fuse individual power consumers changing 136 G...

Page 199: ...r seat mounting 93 removing 92 Play in the clutch lever adjusting 155 Play in throttle cable adjusting 153 Preparing for use advice on first use 66 after storage 166 checks and maintenance when prepar...

Page 200: ...ical system 175 engine 170 engine tightening torques 171 fork 176 shock absorber 176 tires 176 Throttle cable play checking 152 Throttle grip 23 Time adjusting 60 Tire air pressure checking 127 Tire c...

Page 201: ...3213561en 3213561en 02 2017 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

Page 202: ...S standards Operation is subject to the following two conditions 1 this device may not cause interference and 2 this device must accept any interference including interference that may cause undesired...

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