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KTM 1290 SUPERDUKE R, Owner'S Manual, Page: 108 / 213

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KTM 1290 SUPERDUKE R Owner'S Manual Download Page 108

13

SERVICE WORK ON THE CHASSIS

106

Warning

Danger of accidents

 

Reduced braking efficiency due to oil or grease on the brake discs.

–

Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Warning

Environmental hazard

 

Hazardous substances cause environmental damage.

–

Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

The service life of the chain depends largely on its maintenance.

400725-01

–

Clean the chain regularly.

–

Rinse off loose dirt with a soft jet of water.

–

Remove old grease remains with chain cleaner.

Chain cleaner (

p. 199)

–

After drying, apply chain spray.

Chain lube for road use (

p. 199)

Summary of Contents for 1290 SUPERDUKE R

Page 1: ...OWNER S MANUAL 2016 1290 Super Duke R Art no 3213400en...

Page 2: ......

Page 3: ...viations resulting from continuing development and design can however not be completely excluded All specifications are non binding KTM Sportmotorcycle GmbH specifically reserves the right to modify o...

Page 4: ...r 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 T V...

Page 5: ...ce 23 4 VIEW OF VEHICLE 24 4 1 View of vehicle front left example 24 4 2 View of vehicle rear right example 26 5 SERIAL NUMBERS 28 5 1 Chassis number 28 5 2 Type label 28 5 3 Key number 29 5 4 Engine...

Page 6: ...9 14 Temp 60 7 9 15 Pressure 61 7 9 16 Fuel Cons 61 7 9 17 Clock Date 62 7 9 18 Shift Light 62 7 9 19 Heat Grip 63 7 9 20 DRL 63 8 ERGONOMICS 64 8 1 Handlebar position 64 8 2 Adjusting the handlebar p...

Page 7: ...g the passenger seat 100 13 7 Removing the front rider s seat 100 13 8 Mounting the front rider s seat 101 13 9 Mounting the helmet lock on the vehicle 101 13 10 Disassembling the main silencer 102 13...

Page 8: ...hecking the engine oil level 165 19 2 Changing the engine oil and oil filter cleaning the oil screens 166 19 3 Adding engine oil 170 20 CLEANING CARE 173 20 1 Cleaning motorcycle 173 20 2 Checks and m...

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

Page 12: ...that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken Note In...

Page 13: ...11...

Page 14: ...2 SAFETY ADVICE 12 2 4 Overview of labels L01488 10...

Page 15: ...e label for Canada 3 Information on suspension setting 3 Information on chain tension 3 Technical Information 4 Information on preparations for use 5 Information on noise emissions 6 Information on em...

Page 16: ...2 SAFETY ADVICE 14 C00937 01 Type label for Canada L01470 01 Information on suspension setting...

Page 17: ...2 SAFETY ADVICE 15 L01472 01 Information on chain tension L01475 01 Technical Information...

Page 18: ...2 SAFETY ADVICE 16 L01471 01 Information on preparations for use C00938 01 Information on noise emissions...

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

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

Page 21: ...ness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Warnin...

Page 22: ...ts 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 damage an...

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

Page 24: ...ironmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Use operating and auxiliary substances such as...

Page 25: ...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 26: ...4 VIEW OF VEHICLE 24 4 1 View of vehicle front left example L01493 10...

Page 27: ...2 Supporting strap p 43 3 Tool set p 42 4 Seat lock p 41 5 Passenger footrests p 44 6 Rider footrests 7 Shift lever p 44 8 Side stand p 46 9 Shock absorber spring preload setting 10 Cooling system com...

Page 28: ...4 VIEW OF VEHICLE 26 4 2 View of vehicle rear right example L01491 10...

Page 29: ...lock p 37 4 Fork compression adjustment 5 Emergency OFF switch p 36 5 Electric starter button p 37 6 Throttle grip p 33 7 Hand brake lever p 32 8 Fork rebound adjustment 9 Foot brake lever p 45 10 Co...

Page 30: ...number 402324 10 The chassis number 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 The type label USA is located...

Page 31: ...ode number can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place With the orange programming key you can activate or deactivate the bla...

Page 32: ...SERIAL NUMBERS 30 5 4 Engine number 402296 10 The engine number is stamped on the right side of the engine 5 5 Fork part number 402295 10 The fork part number is stamped on the inside of the axle clam...

Page 33: ...98 10 The shock absorber article number 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 34: ...fitted on the handlebar on the left The clutch is activated hydraulically and adjusts itself automatically 6 2 Hand brake lever L01408 11 The hand brake lever is fitted on the right side of the handle...

Page 35: ...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 L01406 10 Overview of the left combination switch 1 Light switc...

Page 36: ...Hazard warning flasher switch L01406 11 The hazard warning flasher switch is fitted on the combination switch on the left The hazard warning flasher is used to indicate emergency situations Info The...

Page 37: ...nal switch L01406 13 The turn signal switch is fitted on the combination switch on the left Possible states Turn signal off Press the turn signal switch Turn signal left on Turn signal switch pressed...

Page 38: ...right side of the handlebar 6 5 1 Emergency OFF switch L01409 10 The emergency OFF switch is fitted on the right side of the handlebar Possible states Emergency OFF switch off In this position the ign...

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

Page 40: ...is may cause mutual interference A lost black ignition key must be deactivated to prevent unauthorized persons from operat ing the vehicle The black ignition keys are activated when delivered Another...

Page 41: ...contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that has been contaminated with fuel Store fuel properly in a suitable canister...

Page 42: ...ey breakage To take pressure off of the ignition key push down on the filler cap Damaged igni tion keys must be replaced Turn ignition key clockwise Fold open filler cap 6 9 Closing the filler cap L01...

Page 43: ...armful to your health After closing the filler cap ensure that it is locked properly Change cloth ing that has been contaminated with fuel Immediately clean contaminated areas on the skin with soap an...

Page 44: ...he 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 lugs Maximu...

Page 45: ...449 10 Warning Danger of accidents Impairment of vehicle handling and vehicle operation if a hel met or helmet lock is attached to the vehicle Do not use the helmet lock for holding a helmet or other...

Page 46: ...footrests can be folded up and down Possible states Passenger footrests folded up For operation without a passenger Passenger footrests folded down For operation with a passenger 6 16 Shift lever 4022...

Page 47: ...ositions can be seen in the figure The idle position is between the first and second gears 6 17 Foot brake lever 402301 10 Foot brake lever is located in front of the right footrest The rear brake is...

Page 48: ...olded 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 s...

Page 49: ...nstrument is activated when the ignition is switched on Info The brightness of the displays is controlled by a brightness sensor in the combina tion instrument Test The segment display the indicator l...

Page 50: ...is due If the General warning lamp lights up among the indicator lamps p 49 the corre sponding message appears in the matrix display The Set button is used to confirm receipt of the information and th...

Page 51: ...lay The left turn signal lamp flashes green simultaneously with the turn signal The left turn signal is switched on The idle indicator lamp lights up green The transmission is shifted to idle The righ...

Page 52: ...Switch off the engine immediately Contact an authorized KTM workshop Engine oil level The engine oil level is too low Check the engine oil level and correct it Lighting system Lights up if an element...

Page 53: ...01 The shift warning light flashes or lights up when the transmission should be shifted In the Shift Light menu the engine speed for the shift warning light can be set The shift warning light flashes...

Page 54: ...found in the service schedule 7 9 Matrix display menu 7 9 1 Favorites L01440 10 Press the UP or DOWN button until the Favorites menu appears on the matrix display Pressing the SET button opens the me...

Page 55: ...range with the fuel reserve Press and hold the button for 3 5 seconds All entries in the Trip 1 menu are cleared 7 9 3 Trip 2 401825 01 Press the UP or DOWN button until the Trip 2 menu appears on th...

Page 56: ...overed Battery indicates the battery voltage Oil Temp indicates the engine oil temperature 7 9 5 Set Favorites L01441 10 Condition The vehicle is stationary Press the UP or DOWN button until the Set F...

Page 57: ...s or various values are made in the Settings menu Several functions can be enabled or disabled 7 9 7 Warning L01435 10 Condition Message or warning Press the UP or DOWN button until the Warning menu a...

Page 58: ...MTC ABS menu appears on the matrix display In the MTC ABS menu MTC and ABS can be switched off In ABS Mode a choice can be made between Road and SUP MOT Info After the ignition is switched on traction...

Page 59: ...ton can be used to select engine and traction control settings that are coordinated with each other SPORT homologated performance with very direct response the traction control allows greater slip on...

Page 60: ...7 COMBINATION INSTRUMENT 58 7 9 11 Menu overview L01438 10...

Page 61: ...sages Heat Grip optional MTC ABS Drive Mod 7 9 12 Language 402431 10 Condition The vehicle is stationary Press the UP or DOWN button until the Settings menu appears on the matrix display Pressing the...

Page 62: ...matrix dis play Pressing the SET button again sets the unit of measure Select kilometers km or miles mi for the distance 7 9 14 Temp 402431 12 Condition The vehicle is stationary Press the UP or DOWN...

Page 63: ...dis play Pressing the SET button again sets the unit of measure Select bar or psi for the tire pressure display 7 9 16 Fuel Cons 402431 14 Condition The vehicle is stationary Press the UP or DOWN but...

Page 64: ...ime and date must be set in the matrix display 7 9 18 Shift Light L01433 10 Condition The vehicle is stationary Press the UP or DOWN button until the Settings menu appears on the matrix display Pressi...

Page 65: ...n switches the heated grips menu on or off Switch the heated grips menu on and off 7 9 20 DRL L01439 16 Condition The vehicle is stationary Press the UP or DOWN button until the Settings menu appears...

Page 66: ...vehicle on a race track 8 2 Adjusting the handlebar position Warning Danger of accidents Handlebar breakage If the handlebar is bent or straightened it will cause material fatigue and the handlebar ca...

Page 67: ...lever L01414 10 Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and...

Page 68: ...brake lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Push the hand brake lever forward and turn the adjusting wheel Do not...

Page 69: ...he foot brake lever using screw in a drill hole Guideline Standard Middle hole Tighten screw Guideline Screw step plate for foot brake lever M6 10 Nm 7 4 lbf ft Loctite 243 8 7 Checking the basic posi...

Page 70: ...t the basic position of the shift lever p 68 8 8 Adjusting the basic position of the shift lever L01417 10 Loosen nut holding the threaded rod Info Nut has a left handed thread Loosen nut holding the...

Page 71: ...ting the shift lever stub L01460 10 Remove screw along with the shift lever stub Position the shift lever stub with the screw in one of the drilled holes depending on the desired lever length Guidelin...

Page 72: ...crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control...

Page 73: ...et 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 Get us...

Page 74: ...t and secure suitcase and tank rucksack according to the manufacturer s instructions Warning Danger of accidents Unstable handling characteristics at high speed Adapt your speed according to your payl...

Page 75: ...xhaust system can burn baggage Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system If you carry luggage make sure you secure it firmly as close as possible t...

Page 76: ...level p 121 Check the front brake linings p 120 Check the brake linings of the rear brake p 124 Check that the brake system is functioning properly Check the coolant level in the compensating tank p 1...

Page 77: ...aged Never operate the vehicle with a discharged battery or without a battery Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always war...

Page 78: ...transmission is in neutral or if the clutch lever is pulled when a gear is engaged If the side stand is folded out and you shift into gear the engine stops Remove the motorcycle from the side stand 1...

Page 79: ...the minimum age of passengers Warning Danger of accidents Danger of accidents caused by dangerous driving Comply with traffic regulations and ride defensively and foresightedly to detect sources of d...

Page 80: ...vehicle as usual before preparing for use Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never operate the vehicle without an air filter as dust and...

Page 81: ...erate very carefully Brake if necessary and close the throttle at the same time in order to shift down Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the th...

Page 82: ...and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Failure of brake system If the foot brake lever is not released the brake linings drag continu...

Page 83: ...he road condi tions and your driving ability When braking release 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 e...

Page 84: ...mponents such as exhaust system radiator engine shock absorber and the brake system Allow these components to cool down before starting work on them Note Material damage The vehicle may be damaged by...

Page 85: ...d with your foot as far as it will go and lean the vehicle on it Lock the steering by turning the handlebar to the left pressing the black ignition key down in the position OFF and turning it to the p...

Page 86: ...w the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If co...

Page 87: ...danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system L01422 10 Switch off the engine Open the filler cap p 38 Fill the fuel tank with fuel up to th...

Page 88: ...trical equipment is functioning properly Change the engine oil and oil filter and clean the oil screens p 166 Check the brake discs p 117 Check the front brake linings p 120 Check the brake linings of...

Page 89: ...n the air filter box Check the cables for damage and routing without sharp bends fuel tank removed Change the spark plugs air filter removed Check the valve clearance air filter and spark plugs remove...

Page 90: ...eck the wheel bearings Grease 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...

Page 91: ...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 determ...

Page 92: ...fork Info The hydraulic rebound damping determines the fork suspension behavior 500311 10 Turn the red adjusting screw all the way clockwise Info Adjusting screw is located at the upper end of the ri...

Page 93: ...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 94: ...help Info The effect of the low speed setting can be seen in slow to normal compression of the shock absorber 500312 10 Turn adjusting screw clockwise with a screwdriver up to the last perceptible cli...

Page 95: ...will be glad to help Info The effect of the high speed setting can be seen in fast compression of the shock absorber 500314 10 Turn adjusting screw all the way clockwise with a socket wrench Info Do...

Page 96: ...he last perceptible click Turn counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 15 clicks Standard 12 clicks Sport 9 clicks Full payl...

Page 97: ...or the weight of the rider and that of any luggage and a passenger thus ensuring an ideal compromise between maneuverability and stability Preparatory work Condition The swingarm is unloaded L01456 10...

Page 98: ...surement Guideline Spring preload Comfort 5 mm 0 2 in Standard 5 mm 0 2 in Sport 6 mm 0 24 in Full payload 7 mm 0 28 in Info Turn clockwise to increase the spring preload turn counterclockwise to redu...

Page 99: ...n a firm and even surface L01445 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 cy...

Page 100: ...ger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Preparatory work Lift the motorcycle with the rear lifting gear p 97 L01446 01 Main work...

Page 101: ...place the vehicle on a firm and even surface L01478 01 Secure the motorcycle against falling over Remove the front lifting gear 13 5 Removing the passenger seat L01428 10 Insert the ignition key in se...

Page 102: ...tion locking pin in the lock housing and push down the passenger seat at the front The locking pin engages with an audible click Check that the passenger seat is correctly mounted 13 7 Removing the fr...

Page 103: ...the recess Check that the front rider s seat is correctly mounted Finishing work Mount the passenger seat p 100 13 9 Mounting the helmet lock on the vehicle Warning Danger of accidents Impairment of...

Page 104: ...e loop around catch Steel cable 60012015000 Pass the steel cable through the helmet opening Position the other loop of the steel cable around catch Carefully position the helmet on the back of the veh...

Page 105: ...13 SERVICE WORK ON THE CHASSIS 103 202959 11 Remove screw with the washer Take off the main silencer 202960 11 Remove seal ring...

Page 106: ...HE CHASSIS 104 13 11 Installing the main silencer 202960 10 Mount seal ring 202959 11 Position the main silencer Mount screw with the washer but do not tighten yet Guideline Remaining screws chassis M...

Page 107: ...Tighten screw Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft 13 12 Checking the chain for dirt 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chai...

Page 108: ...tal hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info The service life of the c...

Page 109: ...loose however it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine Ensure that the chain tension is correct and adjust it if necessary L01425 10 Place th...

Page 110: ...r transmission chain engine sprocket rear sprocket bearings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the counte...

Page 111: ...to increase the chain tension turn counterclockwise to reduce the chain tension Check the chain tension p 107 The chain tension is equal to the specified value Info Chain wear is not always even so y...

Page 112: ...ar sprocket motor sprocket and chain guide 100132 10 Check the rear sprocket and motor sprocket for wear If the rear sprocket or engine sprocket is worn Change the drivetrain kit Info The motor sprock...

Page 113: ...Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance at the longest chain section 272 mm 10 71 in If distance is greater than the specifie...

Page 114: ...the chain is no longer visible at the bottom edge of the recess of the chain sliding guard Change the chain sliding guard Check that the chain sliding guard is firmly seated If the chain sliding guar...

Page 115: ...the screw on the chain sliding piece Guideline Remaining screws chassis M8 25 Nm 18 4 lbf ft 13 17 Checking correcting the fluid level of the hydraulic clutch Info The fluid level rises with increasin...

Page 116: ...fluid level The fluid level must be between the MIN and MAX markings If the fluid level does not meet specifications Remove the screw cap with the membrane Correct the fluid level of the hydraulic clu...

Page 117: ...ot function optimally Optimal function ing of the ABS is only ensured if the brake system only contains spare parts and tires that have been approved and or recommended by KTM Service work and repairs...

Page 118: ...hed on and go out after starting off If it does not go out after starting off or if it is lit while riding this indicates a fault in the ABS system In this case the ABS is no longer enabled and the wh...

Page 119: ...discs at multiple points on each brake disc to ensure it is at least thickness Info Wear will reduce the thickness of the brake disc at the contact surface of the brake linings Brake discs wear limit...

Page 120: ...luid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help L01427 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal p...

Page 121: ...fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil g...

Page 122: ...d immediately with water 14 5 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized...

Page 123: ...brake linings 14 6 Checking the rear brake fluid level Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicates a leakage in the brake s...

Page 124: ...ystem and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep ou...

Page 125: ...brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Preparatory work Che...

Page 126: ...y damaged brake discs If the brake linings are not changed in time the steel brake lining carriers grind on the brake disc The braking effect is greatly reduced and the brake discs are destroyed Check...

Page 127: ...lipers 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 309488 10 Loosen screws and Unscrew screw about six t...

Page 128: ...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 the shaft seal rings and matin...

Page 129: ...n of travel 309492 10 Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleane...

Page 130: ...he hand brake lever in the activated posi tion The brake calipers straighten Tighten screws on both brake calipers Guideline Screw front brake caliper M10 45 Nm 33 2 lbf ft Loctite 243 Remove the fixa...

Page 131: ...t the motorcycle with the rear lifting gear p 97 Disassemble the main silencer p 102 L01463 10 Main work Remove the inside locking wire Remove the outside locking wire L01464 10 Have an assistant oper...

Page 132: ...g efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents No braking effect w...

Page 133: ...ing Clean and grease the threads of the wheel axle and axle nut Long life grease p 199 Slide the rear wheel onto the axle Driving pins engage in drilled holes of the rim 203021 11 Mount taper ring was...

Page 134: ...of a flat tire In the interest of safety replace damaged or worn tires immediately Your authorized KTM workshop will be glad to help Warning Danger of crashing Poor vehicle handling due to different...

Page 135: ...been run in Info Tire type tire condition and tire air pressure influence the braking and handling characteristics of the vehicle Worn tires are particularly unfavorable on wet surfaces 400602 10 Che...

Page 136: ...ear If the tire is 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 en...

Page 137: ...Info Note the legal regulations regarding the daytime running light 16 2 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of...

Page 138: ...t p 99 Remove the front rider s seat p 100 L01482 10 Main work Remove screw Lift cover at the rear and pull toward the rear Fold up the cover L01483 10 Disconnect negative cable of the battery Remove...

Page 139: ...e battery Only charge in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a ph...

Page 140: ...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 Position negative cable and mount and tighten the screw Guideline...

Page 141: ...LECTRICAL SYSTEM 139 L01486 10 Position cover Screw heads engage in recesses Mount and tighten screw Finishing work Mount the front rider s seat p 101 Mount the passenger seat p 100 Set the time and d...

Page 142: ...of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Warning Environmental hazard The battery contains elements that are harmful to the environmen...

Page 143: ...be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and sulfate destroying the battery The battery is maintenance free i e the ac...

Page 144: ...tery 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 of...

Page 145: ...483 12 Mount positive terminal cover Position negative cable and mount and tighten the screw Guideline Screw battery terminal M6 4 5 Nm 3 32 lbf ft L01486 11 Position cover Screw heads engage in reces...

Page 146: ...e electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never bypass or repair fuses Preparatory work Switch off all power consumers and switch of...

Page 147: ...rned out fuse wire A spare fuse is located in the starter relay The main fuse protects all power consumers of the vehicle Install a new main fuse Fuse 58011109130 p 188 Check that the electrical equip...

Page 148: ...LECTRICAL SYSTEM 146 L01486 11 Position cover Screw heads engage in recesses Mount and tighten screw Finishing work Mount the front rider s seat p 101 Mount the passenger seat p 100 Set the time and d...

Page 149: ...scribed amperage Never bypass or repair fuses Info The fuse box containing the fuses of individual power consumers is located under the seat Preparatory work Switch off all power consumers and switch...

Page 150: ...ctive fuse Guideline Fuse res 10 A spare fuses Fuse 1 10 A power supply for control units and components Fuse 2 10 A permanent positive for auxiliary equipment ACC1 Fuse 3 15 A ABS hydraulic unit Fuse...

Page 151: ...187 Fuse 58011109125 p 188 Tip Insert a spare fuse so that it is available if needed Check that the power consumer is functioning properly Close the fuse box cover L01486 11 Position cover Screw heads...

Page 152: ...nger seat p 100 16 7 Changing the headlight bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep...

Page 153: ...00336 10 Detach retaining clamp Remove bulb Position the new bulb in the headlight housing Low beam high beam H4 socket U37R p 188 Info Insert the headlight bulb so that the catches latch into the rec...

Page 154: ...and be deposited on the reflector Clean the lamp and keep it free of grease before mounting L01485 10 Remove the screw on the front of the turn signal housing Carefully remove diffuser Push bulb ligh...

Page 155: ...the low beam headlight Make another mark at a distance under the first mark Guideline Distance 5 cm 2 in Position the vehicle perpendicular to the wall at a distance from the wall and switch on the l...

Page 156: ...ross head screwdriver 53012024100 Info Turn clockwise to increase the headlight range turn counterclockwise to reduce the headlight range If you have a payload you may have to correct the headlight ra...

Page 157: ...on procedure are invalid but can be reprogrammed in a further activation procedure 401114 10 Loss of a black ignition key additional black ignition keys are available The following procedure deactivat...

Page 158: ...number of func tional black ignition keys including the orange programming key In this case it flashes twice Switch off the ignition by turning the orange programming key to the position OFF Pull out...

Page 159: ...All black ignition keys are deactivated Order a new black ignition key according to the key number on the KEYCODECARD and activate it To activate up to three black ignition keys Press the emergency OF...

Page 160: ...nition keys Press the emergency OFF switch to the position ON Insert the orange programming key in the ignition lock Switch on the ignition by turning the orange programming key to the position ON Imm...

Page 161: ...16 ELECTRICAL SYSTEM 159 Info After the fourth black ignition key has been activated programming is fin ished...

Page 162: ...rs with the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed con tact a physician immediately Change...

Page 163: ...lding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs wit...

Page 164: ...work Pull off the compensating tank toward the bottom and maneuver it out L01455 10 Remove cover of the compensating tank Add coolant to the MAX marking Coolant p 196 Mount the cover of the compensat...

Page 165: ...can choose from SPORT STREET and RAIN The drive mode selected last is displayed on the right in the segment display Info The drive mode selection has no influence on the ABS 18 2 Motorcycle traction c...

Page 166: ...18 ENGINE TUNING 164 Info When traction control is active the TC lamp flashes When traction control is switched off the TC lamp is lit...

Page 167: ...Check the engine oil level in the engine oil level viewer Info After switching off the engine wait one minute before checking the level The engine oil level should be in the upper area of the engine o...

Page 168: ...gloves In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be d...

Page 169: ...th the O ring 500340 10 Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing area 500341 10 Insert th...

Page 170: ...ws Guideline Remaining engine screws M5 6 Nm 4 4 lbf ft 100773 12 Thoroughly clean magnet and oil screen of the oil drain plugs 500338 10 Mount and tighten the oil drain plugs with the magnet O rings...

Page 171: ...tity approx 3 0 l 3 2 qt Outside temperature 0 C 32 F Engine oil SAE 10W 50 p 196 Outside temperature 0 C 32 F Engine oil SAE 5W 40 p 197 Mount screw plug Danger Danger of poisoning Exhaust gases are...

Page 172: ...t ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight Finishing work Check the engine oil...

Page 173: ...he engine oil level viewer Condition Outside temperature 0 C 32 F Engine oil SAE 10W 50 p 196 Condition Outside temperature 0 C 32 F Engine oil SAE 5W 40 p 197 Info In order to achieve optimal engine...

Page 174: ...sult in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extra...

Page 175: ...e fluid etc should be disposed of as stipulated in applicable regulations Info If you clean the motorcycle regularly its value and appearance will be maintained over a long period Avoid direct sunshin...

Page 176: ...to evaporate Push back the protection caps of the handlebar controls to allow any water that has penetrated to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Cle...

Page 177: ...riding Warm water would enhance the corrosive effects of salt 401060 01 Clean the motorcycle p 173 Clean the brakes Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake l...

Page 178: ...20 CLEANING CARE 176 Clean the chain p 105...

Page 179: ...en refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 199 Refuel p 84 Clean the motorcycle p 173 Change the engine oil and oil filter and clean t...

Page 180: ...nly 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 t...

Page 181: ...cuit current The safety start system is faulty Read out the fault memory using the KTM diag nostics tool CAN bus communication error Read out the fault memory using the KTM diag nostics tool Fault in...

Page 182: ...ABS fuse is blown Change the fuses in the fuse box p 147 Large difference in wheel speeds of the front and rear wheels Stop the vehicle switch off the ignition and start it again Malfunction in ABS Re...

Page 183: ...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 184: ...lug NGK LMAR7A 9 Electrode gap spark plug 0 9 mm 0 035 in Cooling Water cooling permanent circulation of coolant by water pump Cold start device Electric starter 23 2 Engine tightening torques Screw d...

Page 185: ...over M6 10 Nm 7 4 lbf ft Screw clutch spring M6 12 Nm 8 9 lbf ft Screw coolant connection on cylinder head M6 10 Nm 7 4 lbf ft Screw engine case M6x60 10 Nm 7 4 lbf ft Screw engine case M6x80 10 Nm 7...

Page 186: ...Step 1 10 Nm 7 4 lbf ft Step 2 18 Nm 13 3 lbf ft Screw engine case M8 18 Nm 13 3 lbf ft Screw timing chain guide rail M8 15 Nm 11 1 lbf ft Loctite 243 Stud exhaust flange M8 10 Nm 7 4 lbf ft Timing ch...

Page 187: ...8 9 lbf ft Rotor screw M12x1 5 90 Nm 66 4 lbf ft Spark plug M12x1 5 18 Nm 13 3 lbf ft Nut of engine sprocket M20x1 5 100 Nm 73 8 lbf ft Loctite 243 Oil drain plug M20x1 5 20 Nm 14 8 lbf ft Nut inner...

Page 188: ...Fuel reserve approx 3 5 l 3 7 qt 23 4 Chassis Frame Lattice frame made of chrome molybdenum steel tubing powder coated Fork WP Performance Systems 4860 ROTA SPLIT Shock absorber WP Performance System...

Page 189: ...5 8 x 5 16 525 X ring Steering head angle 65 1 Wheelbase 1 482 mm 58 35 in Seat height unloaded 835 mm 32 87 in Ground clearance unloaded 141 mm 5 55 in Weight without fuel approx 189 kg 417 lb Maximu...

Page 190: ...W Tail light LED Brake light LED License plate lamp LED 23 6 Tires Front tires Rear tires 120 70 ZR 17 M C 58W TL Dunlop Sportmax Sportsmart 190 55 ZR 17 M C 75W TL Dunlop Sportmax Sportsmart Addition...

Page 191: ...mm 54 2 lb in Fork length 776 mm 30 55 in Air chamber length 110 10 30 mm 4 33 0 39 1 18 in Fork oil per fork leg 660 ml 22 31 fl oz Fork oil SAE 4 48601166S1 p 197 23 8 Shock absorber Shock absorber...

Page 192: ...g preload Comfort 5 mm 0 2 in Standard 5 mm 0 2 in Sport 6 mm 0 24 in Full payload 7 mm 0 28 in Spring rate Medium standard 170 N mm 971 lb in Spring length 185 mm 7 28 in Gas pressure 10 bar 145 psi...

Page 193: ...side stand switch M4 2 Nm 1 5 lbf ft Remaining nuts chassis M5 5 Nm 3 7 lbf ft Remaining screws chassis M5 5 Nm 3 7 lbf ft Screw cable channel M5 5 Nm 3 7 lbf ft Screw chain sliding guard M5 5 Nm 3 7...

Page 194: ...pump M6 6 Nm 4 4 lbf ft Screw headlight mask rear wall M6 5 Nm 3 7 lbf ft Screw license plate holder on lower rear panel M6 12 Nm 8 9 lbf ft Screw radiator hose clamp M6 3 Nm 2 2 lbf ft Screw sensor...

Page 195: ...0 Nm 14 8 lbf ft Loctite 243 Screw front brake disc M8 30 Nm 22 1 lbf ft Loctite 2701 Screw front rider footrest bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Scr...

Page 196: ...lbf ft Loctite 243 Screw side stand retaining plate M10 45 Nm 33 2 lbf ft Loctite 243 Banjo bolt brake line M10x1 25 Nm 18 4 lbf ft Banjo bolt brake line connecting piece rear M10x1 15 Nm 11 1 lbf ft...

Page 197: ...10 Nm 7 4 lbf ft Step 2 loosen counterclock wise 60 Nut rear axle shock absorber side M35x1 5 200 Nm 147 5 lbf ft Loctite 262 lock the lock ing wire with locking varnish Nut rear axle M50x1 5 250 Nm 1...

Page 198: ...AKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Only use high quality coolant with corrosion inhibitor for aluminum motors even in countries with high temperatures Using inferior a...

Page 199: ...ication JASO T903 MA p 201 SAE p 201 SAE 5W 40 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties...

Page 200: ...nd that exhibit the corresponding proper ties Super unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equi...

Page 201: ...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 202: ...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 203: ...vice intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated wit...

Page 204: ...fety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces MTC Motorcycle Traction Control Auxiliary function of the motor control which reduce...

Page 205: ...28 LIST OF ABBREVIATIONS 203 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 206: ...d by yellow or orange symbols The general warning lamp lights up yellow An operating safety warning message was detected This is also shown on the matrix display The engine warning lamp lights up flas...

Page 207: ...simultaneously with the turn signal The left turn signal is switched on The idle indicator lamp lights up green The transmission is shifted to idle The right turn signal lamp flashes green simultaneo...

Page 208: ...8 rear brake checking 121 Brake linings front brake checking 120 rear brake checking 124 Brake system 115 124 Brakes 80 C Capacity coolant 186 engine oil 169 185 186 fuel 85 186 Chain checking 110 cle...

Page 209: ...arning 55 Combination switch 33 overview 33 Coolant level compensating tank checking 160 compensating tank correcting 161 Customer service 23 E Electric starter button 37 Emergency OFF switch 36 Engin...

Page 210: ...ng 150 Helmet lock 43 mounting on the vehicle 101 Horn button 36 I Ignition key activating deactivating 155 Ignition lock 37 Immobilizer 38 Implied warranty 22 Intended use 9 K Key number 29 L Light s...

Page 211: ...l installing 130 removing 129 Refueling fuel 84 Riding 76 starting off 76 S Safe operation 19 Seat lock 41 Service 23 Service schedule 86 88 Shift lever 44 basic position adjusting 68 basic position c...

Page 212: ...rques 191 Electrical system 187 Engine 181 195 Engine tightening torques 182 Fork 188 Shock absorber 189 Tires 188 Throttle grip 33 Tire air pressure checking 134 Tire condition checking 132 Tool set...

Page 213: ...3213400en 3213400en 09 2015 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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