KTM 1290 Super Duke R 2017 Owner'S Manual Download | Manualshive

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DEAR KTM CUSTOMER

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Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÜV Management Service

KTM Sportmotorcycle GmbH
5230 Mattighofen, Austria

This document is valid for the following models:
1290 Super Duke R EU (F9903Q9, F9903Q2)
1290 Super Duke R AU (F9960Q9, F9960Q2)
1290 Super Duke R JP (F9986Q2)

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Summary of Contents for 1290 Super Duke R 2017

Page 1: ...OWNER S MANUAL 2017 1290 Super Duke R Art no 3213534en...

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: ...to the international quality management standard ISO 9001 KTM uses quality assurance processes that lead to the maximum possible quality of the products Issued by T V Management Service KTM Sportmotor...

Page 5: ...BERS 22 5 1 Chassis number 22 5 2 Type label 22 5 3 Key number 23 5 4 Engine number 24 5 5 Fork part number 24 5 6 Shock absorber article number 25 5 7 Steering damper article number 25 6 CONTROLS 26...

Page 6: ...7 13 9 Distance 59 7 13 10 Temp 60 7 13 11 Pressure 60 7 13 12 Service 61 7 13 13 Clock Date 61 7 13 14 Shift Light 62 7 13 15 DRL 62 7 13 16 Quick Selector 1 63 7 13 17 Quick Selector 2 64 7 13 18 E...

Page 7: ...3 Recommended work 111 12 SUSPENSION SETTING 113 12 1 Fork shock absorber 113 12 2 Adjusting the compression damping of the fork 113 12 3 Adjusting the rebound damping of the fork 114 12 4 Compression...

Page 8: ...Removing the front wheel 156 15 2 Installing the front wheel 157 15 3 Removing the rear wheel 160 15 4 Installing the rear wheel 161 15 5 Checking the tire condition 163 15 6 Checking the tire air pr...

Page 9: ...ne oil 216 23 3 2 Coolant 216 23 3 3 Fuel 216 23 4 Chassis 216 23 5 Electrical system 218 23 6 Tires 218 23 7 Fork 219 23 8 Shock absorber 220 23 9 Chassis tightening torques 221 24 DECLARATIONS OF CO...

Page 10: ...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 11: ...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 12: ...ded Any use of the vehicle 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 re...

Page 13: ...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 14: ...iousness 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 an enclosed space Warning...

Page 15: ...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 16: ...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 17: ...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 18: ...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 19: ...17...

Page 20: ...4 VIEW OF VEHICLE 18 4 1 View of vehicle front left example S01711 10...

Page 21: ...Supporting strap p 41 3 Tool set p 39 4 Seat lock p 38 5 Passenger footrests p 42 6 Shock absorber spring pretension setting 7 Rider footrests 8 Shift lever p 42 9 Side stand p 44 10 Cooling system co...

Page 22: ...4 VIEW OF VEHICLE 20 4 2 View of vehicle rear right example S01708 10...

Page 23: ...34 4 Emergency OFF switch electric starter button p 33 5 Race on button p 34 6 Throttle grip p 27 7 Hand brake lever p 26 8 Fork compression adjustment 9 Fork rebound adjustment 10 Foot brake lever p...

Page 24: ...er 402324 10 The chassis number 1 is stamped on the right side of the steering head The chassis number is also shown on the type label 5 2 Type label 0 0 1 1 402302 10 Super Duke R EU JP The type labe...

Page 25: ...Duke R AU The type label 1 is located on the frame on the left 5 3 Key number S01733 10 The key number Code number 1 can be found on the KEYCODECARD Info You need the key number to order a spare key K...

Page 26: ...RIAL NUMBERS 24 5 4 Engine number 402296 10 The engine number 1 is stamped on the right side of the engine 5 5 Fork part number 402295 10 The fork part number 1 is stamped on the inside of the axle cl...

Page 27: ...10 The shock absorber article number 1 is stamped on the top of the shock absorber above the adjusting ring towards the engine side 5 7 Steering damper article number H01060 10 Steering damper item n...

Page 28: ...fitted on the handlebar on the left The clutch is activated hydraulically and adjusts itself automatically 6 2 Hand brake lever S01709 10 The hand brake lever 1 is fitted on the right side of the hand...

Page 29: ...the handlebar 6 4 Combination switch left side The left combination switch is fitted on the left side of the handlebar S01713 10 Overview of the left combination switch 1 Light switch p 28 2 Cruise co...

Page 30: ...gh beam and the tail light are switched on Headlight flasher Light switch in position C The headlight flasher is operated in this position The light switch returns automatically to the posi tion A aft...

Page 31: ...ter use Right turn signal on Turn signal switch pressed to the right The turn signal switch returns automatically to the central position after use Info An automatic turn signal switch off function AT...

Page 32: ...s switched on and off The operating mode is displayed in the combination instrument Briefly press cruise control system tip switch in position RES The last saved speed is reapplied Every subsequent br...

Page 33: ...ystem tip switch to the left In addition the cruise control system function is deactivated when one of the following events occurs Operating the hand brake lever Operating the foot brake lever Operati...

Page 34: ...rain ice or snow or unpaved surfaces e g sand stones or gravel Do not use the cruise control systems function if the traffic does not permit a constant speed The cruise control system function cannot...

Page 35: ...l four turn signals and the green turn signal indicator lights in the combination instrument flash 6 12 Emergency OFF switch electric starter button S01717 10 The emergency OFF switch electric starter...

Page 36: ...nd holding switches the ignition off and locks the handlebar 6 14 Steering lock S01723 10 On this vehicle the ignition steering lock is replaced by a remote key with transponder Race on key p 35 In or...

Page 37: ...rm system is installed the Race on indicator lamp 1 flashes when the ignition is switched off and the alarm system is switched on 6 16 Race on key S01724 10 In this vehicle the Race on key 1 performs...

Page 38: ...our keys can be activated from an authorized KTM workshop The key num ber must be provided in each case 6 17 Opening the filler cap Danger Fire hazard Fuel is highly flammable The fuel in the fuel tan...

Page 39: ...case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Warning Environmental hazard Imprope...

Page 40: ...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 Fold down the filler cap 1 and push it down The filler cap...

Page 41: ...fo When the passenger seat is mounted the lugs are accessible if they are turned out ward No more than one small piece of luggage with the specified weight may be attached to the turned out baggage lu...

Page 42: ...Remove the passenger seat p 129 E00713 10 Main work Press in area A in order to open the storage compartment Take off storage compartment Open rubber catch 1 and place item in storage compartment 6 2...

Page 43: ...ristic Do not use the helmet lock to attach a helmet or another object while riding Remove the helmet lock before starting off The steel cable 1 in the tool set can be used to lock a helmet to the veh...

Page 44: ...ootrests can be folded up and down Possible states Passenger footrests folded up For operation without a passenger Passenger footrests folded down For operation with a passenger 6 27 Shift lever 40229...

Page 45: ...sitions can be seen in the figure The idle position is between the first and second gears 6 28 Foot brake lever 402301 10 Foot brake lever 1 is located in front of the right footrest The rear brake is...

Page 46: ...folded up during motorcycle use The side stand is coupled with the safety starting system see the instructions in the Stopping parking chapter Possible states Side stand folded out The vehicle can be...

Page 47: ...nction areas Display 1 2 Indicator lamps p 48 7 2 Activation and test S01734 10 Activation The combination instrument is activated when the ignition is switched on Info The brightness of the displays...

Page 48: ...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 49: ...lamp lights up among the indicator lamps p 48 the corre sponding message appears in the display The Set button is used to confirm receipt of the information and the message is cleared All existing wa...

Page 50: ...7 COMBINATION INSTRUMENT 48 7 5 Indicator lamps M01492 01...

Page 51: ...hes yellow Traction control is not enabled or is currently intervening The TC Indi cator lamp also lights up if an error is detected The TC indicator lamp flashes if the launch control optional is act...

Page 52: ...7 COMBINATION INSTRUMENT 50 7 6 Display M01493 10...

Page 53: ...ments shown change and the display colors change 1 Tachometer 1 Shift warning light p 52 The shift warning light is integrated in the tachometer display 2 Fuel level display p 52 3 Time p 53 4 Coolant...

Page 54: ...perature 35 C 95 F The shift warning light always lights up at 6 500 rpm 7 8 Fuel level display E00719 10 The fuel level indicator consists of bars The more bars are lit the more fuel is in the fuel t...

Page 55: ...t after the battery was disconnected or the fuse was removed 7 10 Coolant temperature indicator E00729 01 The coolant temperature indicator consists of bars The more bars that light up the hotter the...

Page 56: ...n be accessed in the General Info menu under menu item ODO The trip distance counter can be configured in the Trip 1 menu Information about other distances traveled can be accessed and configured in t...

Page 57: ...e current menu or the menu overview 7 13 1 Favorites K00751 01 Press the SET button when the menu is closed Access the menu by pressing the SET button again Select the required menu item using the UP...

Page 58: ...T button when the menu is closed Press the UP or DOWN button until the Trip 1 menu appears on the display Trip 1 shows the distance since the last reset such as between two refueling stops Trip 1 is r...

Page 59: ...fuel consumption based on Trip 2 Trip Time 2 shows the journey time on the basis of Trip 2 and runs as soon as there is a speed signal Fuel Range indicates the possible distance you can cover with th...

Page 60: ...DOWN button until the desired language is marked Select the language using the SET button The menu languages are US English UK English German Italian French and Spanish 7 13 7 Unit settings K00764 01...

Page 61: ...r DOWN button until the desired unit appears on the display Press the SET button again to confirm the desired unit 7 13 9 Distance K00777 01 Condition The vehicle is stationary Press the SET button wh...

Page 62: ...il the desired unit appears on the display Press the SET button again to confirm the desired unit 7 13 11 Pressure K00779 01 Condition The vehicle is stationary Press the SET button when the menu is c...

Page 63: ...hown in the Service menu 7 13 13 Clock Date K00763 01 Condition The vehicle is stationary Press the SET button when the menu is closed Press the UP or DOWN button until the Settings menu appears on th...

Page 64: ...he display Pressing the SET button again opens the menu Press the UP or DOWN button to select the function Use the SET button to set the engine speed for the shift warning light When the engine speed...

Page 65: ...ons regarding the daytime running light Press the UP or DOWN button until DRL appears marked on the display Pressing the SET button again switches the daytime running light on or off 7 13 16 Quick Sel...

Page 66: ...he UP or DOWN button until the Settings menu appears on the display Press the SET button Press the UP or DOWN button until the Quick Selector menu appears on the display Press the SET button to open t...

Page 67: ...ons Info The optional extra functions are listed in Extra Functions The current KTM Power Parts and the available software for your vehicle can be found on the KTM web site 7 13 19 General Info K00780...

Page 68: ...K00757 01 Condition The vehicle is stationary Warning Voiding of the government approval for road use and the insurance coverage If the ABS is switched off completely the vehicle s approval for road u...

Page 69: ...e K00752 01 Press the SET button when the menu is closed Press the UP or DOWN button until the Ride Mode menu appears on the display Press SET button Use the UP or DOWN button to navigate through the...

Page 70: ...the tire pressure deviates from the specified value Even if the tire pressure values are correct stop the vehicle immediately if its behavior indicates a pressure loss in the tires Press the SET butto...

Page 71: ...ked on the display Pressing the SET button again switches the heated grips menu on or off 7 16 Heating optional K00756 01 Condition The Heated grips menu is activated Press the SET button when the men...

Page 72: ...r DOWN button until Quick Shift appears marked on the display Switch Quickshifter p 96 on and off using the SET button 7 18 Track optional K00753 01 Condition The drive mode TRACK optional is activate...

Page 73: ...Wheelie Mode if you have the appropriate experi ence Switch the launch control on and off using the SET button 7 20 Anti Wheelie Mode optional K00753 01 Condition The drive mode TRACK optional is act...

Page 74: ...y be used in conjunction with KTM MY RIDE optional When the Bluetooth function is switched on the Bluetooth symbol appears and flashes in the display of the combination instrument The Bluetooth symbol...

Page 75: ...tton until the KTM MY RIDE menu appears on the display Press the SET button to open the menu Press the UP or DOWN button until KTM MY RIDE Setup appears marked on the display Press the SET button Pres...

Page 76: ...lly completes the pairing Info When a suitable device has been successfully paired the name of the paired cellphone or headset appears in each case in the PHONE or HEADSET menu Press the UP or DOWN bu...

Page 77: ...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 UP or DOWN button until Audio i...

Page 78: ...e 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 an...

Page 79: ...handlebar can be mounted in the most comfortable position for the rider Info KTM recommends the front handlebar position when using the vehicle on a race track 8 2 Adjusting the handlebar position War...

Page 80: ...move screws 3 Take off handlebar supports 4 Move the handlebar supports into the desired position A or B Mount and tighten screws 3 Guideline Mount the left and right handlebar supports in the same po...

Page 81: ...Only turn the adjusting screw by hand and do not use force Do not make any adjustments while riding 8 4 Adjusting the basic position of the hand brake lever S01729 10 Push the hand brake lever forwar...

Page 82: ...0 Loosen nut 1 Press the foot brake lever down to be able to turn push rod 2 more easily Turn the push rod until the foot brake lever is in the desired position Info The range of adjustment is limited...

Page 83: ...foot brake lever using screw 1 in a drill hole 2 Guideline Standard Middle hole Tighten screw 1 Guideline Screw step plate for foot brake lever M6 10 Nm 7 4 lbf ft Loctite 243 8 7 Checking the basic...

Page 84: ...asic position of the shift lever p 82 8 8 Adjusting the basic position of the shift lever S01732 10 Loosen nut 1 holding the threaded rod 2 Info Nut 1 has a left handed thread Loosen nut 3 holding the...

Page 85: ...ting the shift lever stub E00707 10 Remove screw 1 along with the shift lever stub Position the shift lever stub with the screw in one of the drilled holes 2 depending on the desired lever length Guid...

Page 86: ...the combination instrument Info The tilt of the combination instrument can be continuously adjusted using clamping on the handlebar E00715 11 Unplug the connector 1 with sleeve E00725 10 Remove cable...

Page 87: ...tilt of the combination instrument Info The combination instrument must also not touch any other components follow ing completion of the work Tighten screw 3 using Allen key from the tool set Guideli...

Page 88: ...8 ERGONOMICS 86 E00715 11 Plug in the connector 1 with sleeve...

Page 89: ...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 90: ...y Booklet at vehicle handover Before your first trip read the entire Owner s Manual carefully Get to know the controls Adjust the motorcycle to your requirements as described in the Ergonomics chapter...

Page 91: ...cases and tank rucksack according to the manufacturer s instructions Warning Danger of accidents Unstable handling characteristics at high speed Adapt your speed according to your payload Ride more s...

Page 92: ...d The hot exhaust system may burn luggage Fasten your luggage in such a way that it cannot be burned or singed by the hot exhaust system If you carry luggage make sure you secure it firmly as close as...

Page 93: ...p 152 Check the front brake linings p 151 Check the brake linings of the rear brake p 154 Check that the brake system is functioning properly Check the coolant level in the compensating tank p 189 Che...

Page 94: ...r without a battery Note Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine Always run the engine warm at a low speed E00711 10 Take the motorcycle off s...

Page 95: ...wer position Info Do not press the emergency off switch electric starter button into the lower posi tion until the combination instrument function check has been completed When starting DO NOT open th...

Page 96: ...also deactivated if all conditions for activation are no longer met Launch control is enabled again in the following cases the engine runs for at least three minutes the engine is switched off for 20...

Page 97: ...not have an error stored Coolant temperature 60 C 140 F Total riding distance covered 1 000 km 620 mi Activate launch control in the combination instrument The TC indicator lamp flashes quickly Apply...

Page 98: ...he shifter shaft position to check whether or not a shift should be initiated and sends a corresponding signal to the engine control If the quickshifter is disabled in the combination instrument the c...

Page 99: ...feet on the passenger foot rest and holds on to the rider or the grab handles Note the regulations governing the minimum age of passengers in your country Warning Danger of accidents A risky riding st...

Page 100: ...Danger of accidents A fall can damage the vehicle more seriously than it may first appear Check the vehicle after a fall as you do when preparing for use Note Engine damage Unfiltered intake air has...

Page 101: ...the positions of the 6 forward gears in the figure The 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 ful...

Page 102: ...the display shows a message for 10 seconds Info Very important messages are stored in the Warning menu If the ice warning appears in the combination instrument the roads may be icy Adjust your speed t...

Page 103: ...sition 10 8 MSR optional 402423 01 The MSR is an optional auxiliary function of the engine control If the engine braking effect is too great the MSR prevents the rear wheel from locking or sliding awa...

Page 104: ...ystem fails in the event of overheating If the foot brake lever is not released the brake linings drag continuously Take your foot off the foot brake lever when you are not braking Warning Danger of a...

Page 105: ...the throttle and apply the front and rear brakes at the same time Info When the ABS is enabled you can achieve maximum braking power even on low grip surfaces such as sandy wet or slippery terrain wit...

Page 106: ...touch any parts such as the exhaust system radiator engine shock absorber or brake system before the vehicle parts have cooled down Let the vehicle parts cool down before you perform any work on the v...

Page 107: ...y OFF switch is intended for emergencies only Park the motorcycle on a firm surface Swing the side stand forward with your foot as far as it will go and lean the vehicle on it Move handlebar fully to...

Page 108: ...ire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the e...

Page 109: ...he eyes Change your clothing in case of fuel spills on them Note Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged In some countries and regions the available fu...

Page 110: ...0 Switch off the engine Open the filler cap p 36 Fill the fuel tank with fuel up to the lower edge A of the filler neck Total fuel tank capacity approx 18 l 4 8 US gal Super unleaded ROZ 95 RON 95 PON...

Page 111: ...ult memory using the KTM diagnostics tool Check the exhaust valve control with the KTM diagnostics tool Check that the electrical system is functioning properly Change the engine oil and oil filter an...

Page 112: ...ngine sprocket and chain guide p 139 Check the chain tension p 136 Measure the wheel bearing play and grease the rear hub Check that the rear wheel nut right side is tightened to the specified torque...

Page 113: ...ride using the KTM diagnostics tool Reset the service display using the KTM diagnostic tool Make the service entry in KTM Dealer net and in the Service and Manufacturer Warranty Booklet One time inter...

Page 114: ...e all moving parts e g side stand hand lever chain and check for smooth operation Empty the drainage hoses Check all hoses e g fuel cooling bleeder drainage etc and sleeves for cracking leaks and inco...

Page 115: ...e guidelines are not adhered to the riding characteristics could deteriorate particularly at high speeds 12 2 Adjusting the compression damping of the fork Info The hydraulic compression damping deter...

Page 116: ...fork Info The hydraulic rebound damping determines the fork suspension behavior E00703 10 Turn red adjusting screw 1 clockwise as far as it will go Info Adjusting screw 1 is located at the upper end...

Page 117: ...d 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 an asphalt edge the rear wheel su...

Page 118: ...hop will be glad to help Info The effect of the low speed setting can be seen in slow to normal compression of the shock absorber E00699 10 Turn adjusting screw 1 clockwise with a screwdriver up to th...

Page 119: ...orized KTM workshop will be glad to help Info The effect of the high speed setting can be seen in fast compression of the shock absorber E00700 10 Turn adjusting screw 1 all the way clockwise with a s...

Page 120: ...rized KTM workshop will be glad to help E00698 10 Turn adjusting screw 1 clockwise up to the last perceptible click Turn counterclockwise by the number of clicks corresponding to the shock absorber ty...

Page 121: ...in work Measure the distance as vertical as possible between the rear axle and a fixed point for example a mark on the rear fairing Note down the value as dimension A Finishing work Remove the motorcy...

Page 122: ...difference between measurements A and B Check the static sag Full fuel tank standard 20 mm 0 79 in Full fuel tank race track mode 14 mm 0 55 in If the static sag is less or more than the specified va...

Page 123: ...for the weight of the rider and that of any baggage and a passenger thus ensuring an ideal compromise between maneuverability and stability Preparatory work Condition The swingarm is unloaded E00697 1...

Page 124: ...0 31 in Standard 8 mm 0 31 in Sport 8 mm 0 31 in Full payload 9 mm 0 35 in Info Turn clockwise to increase the spring pretension turn counterclockwise to reduce the spring pretension For race track m...

Page 125: ...n a firm and level surface E00695 01 Place the adapter into the rear lifting gear Lifting gear rear 61329955000 Position the motorcycle upright place the lifting gear in the axle and raise the motor c...

Page 126: ...Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface Preparatory work Lift the motorcycle with the rear lifting gear p 123 E00696 01 Main work M...

Page 127: ...le can roll away or fall over Park the vehicle on a firm and level surface 402777 01 Secure the motorcycle against falling over Remove the front lifting gear 13 5 Raising the motorcycle with the work...

Page 128: ...rm pivot Select the right height and width of the work stand Work stand 62529055100 Raise the motorcycle Info Check that the work stand is properly seated 13 6 Removing the motorcycle from the work st...

Page 129: ...13 SERVICE WORK ON THE CHASSIS 127 R01907 10 Remove the motorcycle from the work stand and rest it on the side stand Remove the work stand Work stand 62529055100...

Page 130: ...hind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake dis...

Page 131: ...it out of the holder toward the front Remove the passenger seat Remove the key 13 9 Mounting the passenger seat 401922 10 Attach the recesses of the passenger seat in the guides 1 and lower at the fr...

Page 132: ...s seat Detach the front of the front rider s seat and remove it 13 11 Mounting the front rider s seat 401921 10 Main work Attach recesses 1 on the front rider s seat to the fuel tank and push the fro...

Page 133: ...ding Remove the helmet lock before starting off E00692 10 Remove the passenger seat p 129 Position steel cable 1 from the tool set with the loop around catch 2 Steel cable 60012015000 Pass the steel c...

Page 134: ...13 SERVICE WORK ON THE CHASSIS 132 R01827 10 Remove screw 2 with the washer Take off the main silencer R01828 10 Remove seal ring 3...

Page 135: ...HE CHASSIS 133 13 14 Installing the main silencer R01828 11 Mount seal ring 1 R01827 10 Position the main silencer Mount screw 2 with washer but do not tighten yet Guideline Remaining screws chassis M...

Page 136: ...screw 2 Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft 13 15 Checking the chain for dirt 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 13...

Page 137: ...agents brake fluid etc correctly and in compliance with the applicable regula tions Info The service life of the chain depends largely on its maintenance Regular cleaning increases the service life o...

Page 138: ...locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Lift the motorcycle with the rear lifting gear p 123 E...

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

Page 140: ...the chain tension turn counterclockwise to reduce the chain tension The tool required is in the tool set Check the chain tension p 136 The chain tension matches the specified value Info Chain wear is...

Page 141: ...de Preparatory work Lift the motorcycle with the rear lifting gear p 123 100132 10 Main work Check the rear sprocket and engine sprocket for wear If the rear sprocket or engine sprocket is worn Change...

Page 142: ...hain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance B at the longest chain section 272 mm 10 71 in If distance B is greater than the speci...

Page 143: ...rivet 1 is no longer visible at bottom edge C of the recess of the chain sliding guard Change the chain sliding guard Check that the chain sliding guard is firmly seated If the chain sliding guard is...

Page 144: ...or below the chain sliding piece Change the chain sliding piece Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the screw on the chain sliding piece Gu...

Page 145: ...ghly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Environmental hazard Hazardous su...

Page 146: ...luid level must be between MIN and MAX markings If the fluid level does not meet specifications Remove screw cap 1 with membrane 2 and the shim Correct the fluid level of the hydraulic clutch Brake fl...

Page 147: ...nsion travel Only use spare 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 t...

Page 148: ...dent brake circuits front and rear brakes When the brake electronics control unit detects a locking tendency in a wheel ABS begins regulat ing the brake pressure The regulating process causes a slight...

Page 149: ...cs Warning Danger of accidents Worn out brake discs reduce the braking effect Make sure that worn out brake discs are replaced immediately Your authorized KTM workshop will be glad to help 100135 10 C...

Page 150: ...fluid level will cause the brake system to fail If the brake fluid level drops below the MIN marking the brake system is leaking or the brake linings are worn down Check the brake system and do not c...

Page 151: ...Check the brake system and do not continue riding until the problem is eliminated Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brak...

Page 152: ...the applicable regula tions Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid...

Page 153: ...aking 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 destroye...

Page 154: ...do not continue riding until the problem is eliminated Your authorized KTM workshop will be glad to help Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fl...

Page 155: ...act with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thor...

Page 156: ...brake p 154 E00682 11 Main work Stand the vehicle upright Remove screw cap 1 with the washer and membrane 2 Add brake fluid up to MAX marking A Brake fluid DOT 4 DOT 5 1 p 229 Mount and tighten screw...

Page 157: ...a consequence the braking effect is greatly reduced and the brake discs are destroyed Check the brake linings regularly 500320 10 Check the brake linings for minimum thickness A Minimum thickness A 1...

Page 158: ...calipers carefully back from the brake discs and hang them to one side Info Do not pull the hand brake lever when the brake caliper has been removed R01778 10 Loosen screws 2 and 3 Unscrew screw 2 abo...

Page 159: ...2 Installing the front wheel 309490 10 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the front wheel bearing Clean and grease shaft seal rings 1 and mating...

Page 160: ...irection of travel R01780 10 Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake...

Page 161: ...nd brake lever in the activated posi tion The brake calipers straighten Tighten screws 5 on both brake calipers Guideline Screw front brake caliper M10 45 Nm 33 2 lbf ft Loctite 243 Remove the locking...

Page 162: ...k Lift the motorcycle with the rear lifting gear p 123 Remove the main silencer p 131 B04149 10 Main work Remove the inside locking wire 1 Remove the outside locking wire 2 B04139 10 Have an assistant...

Page 163: ...he rear wheel 15 4 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake...

Page 164: ...lean and grease the threads of the wheel axle and axle nut Long life grease p 232 Slide the rear wheel onto the axle Driving pins 1 engage in drilled holes A of the rim E00181 10 Mount washer 2 and nu...

Page 165: ...ure that damaged or worn tires are replaced immediately Your authorized KTM workshop will be glad to help Warning Danger of crashing Different tire tread patterns on the front and rear wheel impair th...

Page 166: ...pressure influence the braking and handling characteristics of the vehicle Worn tires are particularly unfavorable on wet surfaces 400602 10 Check the front and rear tires for cuts run in objects and...

Page 167: ...e tires are more than 5 years old Change the tires 15 6 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures o...

Page 168: ...15 WHEELS TIRES 166 Correct the tire pressure Mount the dust cap...

Page 169: ...he low beam is switched on permanently Note the legal regulations regarding the daytime running light The daytime running DRL position light is integrated in the main headlight The daytime running lig...

Page 170: ...rooms Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and...

Page 171: ...1 Lift cover 2 at the rear and pull toward the rear Fold up the cover L01483 10 Disconnect negative cable 3 of the battery Remove positive terminal cover 4 and disconnect the positive cable from the...

Page 172: ...s in well ventilated rooms Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes with water for at least 15 minutes and consult a doctor immediately...

Page 173: ...he positive cable and mount and tighten the screw Guideline Screw battery terminal M6 4 5 Nm 3 32 lbf ft Mount positive terminal cover 3 Position negative cable 4 mount and tighten the screw Guideline...

Page 174: ...RICAL SYSTEM 172 L01486 10 Position cover 1 Screw heads A engage in recesses B Mount and tighten screw 5 Finishing work Mount the front rider s seat p 130 Mount the passenger seat p 129 Set the time a...

Page 175: ...a immediately with plenty of water in the event of contact with the skin Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and battery gases get into the e...

Page 176: ...charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and sulfate destroying the battery The battery is maintenance free i e the acid...

Page 177: ...attery charger to test the open circuit voltage and start potential of the battery and to test the alternator With this device you cannot overcharge the battery Info Charge the battery with a maximum...

Page 178: ...Mount positive terminal cover 4 Position negative cable 3 and mount and tighten the screw Guideline Screw battery terminal M6 4 5 Nm 3 32 lbf ft L01486 11 Position cover 2 Screw heads A engage in rec...

Page 179: ...5 Changing the Race on key battery S01740 10 Fold out the key bit of the Race on key Push the lower half of the Race on key in the direction of the arrow and take off S01739 10 Remove battery cover 1...

Page 180: ...ow 16 6 Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system Only use fuses with the required ampere value Do not bypass or repair fuses Preparatory work Switch of...

Page 181: ...Fold up the cover 500327 11 Take off protection caps 3 C00935 10 Remove faulty main fuse 4 Info You can recognize a faulty fuse by a burned out fuse wire A A spare fuse 5 is located in the starter re...

Page 182: ...ly Mount the protection caps Tip Insert a new spare fuse into the starter relay to have it available when needed M01490 10 Position cover 2 Screw heads B engage in recesses C Mount and tighten screw 1...

Page 183: ...d ampere value Do not 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 switch o...

Page 184: ...16 ELECTRICAL SYSTEM 182 500329 11 Open fuse box cover 3 E00680 10 Check the fuses Info You can recognize a faulty fuse by a burned out fuse wire A Remove the defective fuse...

Page 185: ...ECU Fuse 6 25 A ABS return pump Fuse 7 15 A ABS hydraulic unit Fuse 8 not assigned Fuse 9 not assigned Fuse 10 not assigned Fuse res 10 A spare fuses Fuse res 15 A spare fuse Fuse res 25 A spare fuse...

Page 186: ...16 ELECTRICAL SYSTEM 184 M01490 10 Position cover 2 Screw heads B engage in recesses C Mount and tighten screw 1 Finishing work Mount the front rider s seat p 130 Mount the passenger seat p 129...

Page 187: ...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 The light...

Page 188: ...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 189: ...Diagnostics connector H01949 01 Diagnostics connector 1 is located under the front rider s seat 16 11 ACC1 and ACC2 front E00777 10 Power supplies ACC1 1 and ACC2 2 front are located behind the right...

Page 190: ...16 ELECTRICAL SYSTEM 188 16 12 ACC1 and ACC2 rear E00778 10 Power supplies ACC1 1 and ACC2 2 rear are located under the seat...

Page 191: ...of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach o...

Page 192: ...tank is not empty Correct the coolant level in the compensating tank p 190 17 2 Correcting the coolant level in the compensating tank Warning Danger of scalding During motorcycle operation the coolant...

Page 193: ...octor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediate...

Page 194: ...the compensating tank from the side with the holding lug 1 E00678 10 Remove cover 2 of the compensating tank Add coolant to the MAX marking Coolant p 229 Mount cover 2 of the compensating tank Mount c...

Page 195: ...y set Various vehicle tunings can be selected in the Ride Mode menu SPORT STREET RAIN and TRACK are available optional The drive mode selected last is displayed in the combination instrument The drive...

Page 196: ...the rear wheel and level 9 the minimum The slip adjustment can be set while riding with a closed menu using the UP or DOWN but ton Info The slip adjustment is only available in Ride Mode TRACK p 193 o...

Page 197: ...k the engine oil level in the engine oil level viewer Info After switching off the engine wait one minute before checking the level The engine oil level should be in the upper area B of the engine oil...

Page 198: ...scalding rinse the area affected immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake...

Page 199: ...10 Pull oil filter 4 out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing surfaces E00674 10 Insert new oil filter 4...

Page 200: ...Guideline Remaining engine screws M5 6 Nm 4 4 lbf ft 100773 12 Thoroughly clean magnets A and oil screens B of the oil drain plugs E00672 10 Mount and tighten oil drain plugs 1 with the magnets O rin...

Page 201: ...uantity approx 3 0 l 3 2 qt Outside temperature 0 C 32 F Engine oil SAE 10W 50 p 230 Outside temperature 0 C 32 F Engine oil SAE 5W 40 p 230 Mount screw plug 5 Danger Danger of poisoning Exhaust gases...

Page 202: ...g the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Start the engine and check that it is oil tight Finishing work Check the engine oil lev...

Page 203: ...he engine oil level viewer Condition Outside temperature 0 C 32 F Engine oil SAE 10W 50 p 230 Condition Outside temperature 0 C 32 F Engine oil SAE 5W 40 p 230 Info In order to achieve optimal engine...

Page 204: ...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 an enclo...

Page 205: ...et directly 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...

Page 206: ...clean it with cold water Warm water would 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 s...

Page 207: ...quality Treat the 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 233 Oil steering lock and...

Page 208: ...after the 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 the swingarm and all other ba...

Page 209: ...n refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 232 Refuel p 106 Clean the motorcycle p 203 Change the engine oil and oil filter and clean t...

Page 210: ...ly Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and the exhaust system to rust 21 2 Preparing for use after storage 401059 01 Take th...

Page 211: ...engine only turns if the clutch lever is drawn The vehicle is in gear Shift the transmission to idle The safety start system is faulty Read out the fault memory using the KTM diag nostics tool The en...

Page 212: ...KTM diag nostics tool High oil consumption The engine oil level is too high Check the engine oil level p 195 The engine oil is too thin low viscos ity Change the engine oil and oil filter and clean t...

Page 213: ...aust 34 mm 1 34 in Valve clearance Exhaust at 20 C 68 F 0 25 0 30 mm 0 0098 0 0118 in Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Crankshaft bearing Sleeve bearing Conrod bearing Sleeve bearing...

Page 214: ...Outside spark plug NGK LMAR7DI 10 Electrode gap spark plug 1 mm 0 04 in Cooling Water cooling permanent circulation of coolant by water pump Cold start device Electric starter 23 2 Engine tightening t...

Page 215: ...ew camshaft bearing support M6 10 9 10 Nm 7 4 lbf ft Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch spring M6 12 Nm 8 9 lbf ft Screw engine case M6x60 10 Nm 7 4 lbf ft Screw engine case M6x80 10...

Page 216: ...support M8 10 9 Step 1 8 5 Nm 6 27 lbf ft Step 2 14 5 Nm 10 7 lbf ft Only applies when using Hex key bit 61229025000 Screw engine case M8 18 Nm 13 3 lbf ft Screw timing chain guide rail M8 15 Nm 11 1...

Page 217: ...m 22 1 lbf ft Step 3 90 Step 4 90 Lubricated with engine oil Coolant temperature sensor M12x1 5 12 Nm 8 9 lbf ft Rotor screw M12x1 5 115 Nm 84 8 lbf ft Spark plug M12x1 5 18 Nm 13 3 lbf ft Nut of engi...

Page 218: ...3 20 l 3 38 qt Coolant p 229 23 3 3 Fuel Total fuel tank capacity approx 18 l 4 8 US gal Super unleaded ROZ 95 RON 95 PON 91 p 231 Fuel reserve approx 3 6 l 3 8 qt 23 4 Chassis Frame Lattice frame mad...

Page 219: ...ear 4 5 mm 0 177 in Tire air pressure solo front with cold tires 2 5 bar 36 psi rear with cold tires 2 5 bar 36 psi Secondary drive ratio 17 38 Chain 5 8 x 5 16 525 X ring Steering head angle 65 1 Whe...

Page 220: ...am high beam LED Daytime running light position light LED Instrument lights and indicator lamps LED Turn signal LED Tail light LED Brake light LED License plate lamp LED 23 6 Tires Front tires Rear ti...

Page 221: ...9 clicks Full payload 9 clicks Rebound damping Comfort 15 clicks Standard 12 clicks Sport 9 clicks Full payload 9 clicks Spring length with preload spacer s 255 mm 10 04 in Spring rate Medium standar...

Page 222: ...clicks Standard 15 clicks Sport 12 clicks Full payload 12 clicks Compression damping high speed Comfort 1 5 turns Standard 1 5 turns Sport 1 5 turns Full payload 1 turn Rebound damping Comfort 15 cli...

Page 223: ...Remaining screws chassis EJOT PT K50x16 2 Nm 1 5 lbf ft Remaining screws chassis EJOT PT K50x18 2 Nm 1 5 lbf ft Remaining screws chassis EJOT PT K45x12 1 Nm 0 7 lbf ft Screw air filter box lid EJOT P...

Page 224: ...ft Screw trim M5x12 3 5 Nm 2 58 lbf ft Cable disk nut exhaust valve control unit M6 14 Nm 10 3 lbf ft Ground fitting on frame M6 10 Nm 7 4 lbf ft Nut cable on starter motor M6 4 Nm 3 lbf ft Remaining...

Page 225: ...243 Screw shift shaft deflector on shift shaft M6 18 Nm 13 3 lbf ft Loctite 243 Screw side stand stub M6 6 Nm 4 4 lbf ft Loctite 243 Screw steering damper holder on frame M6 8 Nm 5 9 lbf ft Loctite 2...

Page 226: ...8 4 lbf ft Screw rear brake caliper M8 25 Nm 18 4 lbf ft Loctite 2701 Screw rear brake disc M8 30 Nm 22 1 lbf ft Loctite 243 Screw shift lever on footrest bracket M8 20 Nm 14 8 lbf ft Loctite 243 Scre...

Page 227: ...10x1 25 45 Nm 33 2 lbf ft Loctite 243 Lambda sensor M12x1 25 25 Nm 18 4 lbf ft Screw bottom shock absorber M14x1 5 80 Nm 59 lbf ft Thread greased Screw top shock absorber M14x1 5 80 Nm 59 lbf ft Threa...

Page 228: ...he KTM RACE ON system wireless system conforms with the relevant guidelines The full text of the EU Decla ration of Conformity is available at the following Internet address Certification website http...

Page 229: ...ADI01 IC 22239 KLGMZADI01 LC8 DASHBOARD FCC ID 2AKP9 LC8CLUSTER1 IC 22273 LC8CLUSTER1 Tyre Pressure Monitoring System Receiver MC34MA4 FCC ID MRXMC34MA4 IC 2546A MC34MA4 Tyre Pressure Monitoring Syste...

Page 230: ...they 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 certai...

Page 231: ...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 232: ...ideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Fully synthetic engine oil Recommended supplier...

Page 233: ...ication SAE p 234 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...

Page 234: ...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 235: ...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 236: ...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 237: ...ith transponder Launch Control Vehicles electronics functions for achieving the best possible acceleration from a standing position MSR Motor Slip Regulation Auxiliary function of the motor control wh...

Page 238: ...29 LIST OF ABBREVIATIONS 236 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 239: ...d a fault ABS indicator lamp lights up flashes yellow The ABS is not activated on one or both wheels The ABS indicator lamp also lights up if an error is detected TC indicator lamp lights up flashes y...

Page 240: ...shes green with a steady rhythmic flash The left turn signal is switched on The idle indicator lamp lights up green The transmission is in idle The right turn signal indicator lamp flashes green with...

Page 241: ...ront brake adding 149 Brake fluid level front brake checking 148 rear brake checking 152 Brake linings front brake checking 151 rear brake checking 154 Brake system 145 155 Brakes 102 C Capacity Coola...

Page 242: ...TM MY RIDE 72 Language 58 Launch Control 71 menu 55 MTC 66 overview 45 Pairing 73 Pressure 60 Quick Shift 70 Quick Selector 1 63 Quick Selector 2 64 Ride Mode 67 193 Service 61 Set Favorites 56 Settin...

Page 243: ...l adding 200 changing 196 Engine oil level checking 195 Engine sprocket checking 139 Environment 13 F Figures 16 Filler cap closing 38 opening 36 Foot brake lever 43 basic position adjusting 80 Settin...

Page 244: ...switch 28 Luggage 89 M Main fuse changing 178 Main silencer installing 133 removing 131 Menu switch 28 Misuse 10 Motorcycle cleaning 203 lifting with front lifting gear 124 lifting with rear lifting g...

Page 245: ...94 S Safe operation 12 Seat lock 38 Service 16 Service schedule 109 112 Shift lever 42 basic position adjusting 82 basic position checking 81 Shift lever stub setting 83 Shifting 96 Shock absorber 113...

Page 246: ...ightening torques 212 fork 219 shock absorber 220 tires 218 Throttle grip 27 Tire air pressure checking 165 Tire condition checking 163 Tool set 39 Transport 105 Troubleshooting 209 210 Turn signal sw...

Page 247: ...3213534en 3213534en 04 2017 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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