KTM 2015 200 Duke Owner'S Manual Download

Page: 140 / 177

TUNING THE ENGINE

138

» If the clutch lever play changes:

–

Check the routing of the clutch cable.

16.4

Adjusting the clutch cable play

M00007-10

–

Move the handlebar to the straight-ahead position.

–

Push back sleeve



–

Loosen lock nut



–

Adjust the play in the clutch level



by turning adjusting screw



Guideline

Clutch lever play

1… 3 mm (0.04… 0.12 in)

–

Tighten lock nut



–

Slide on sleeve



Summary of Contents for 2015 200 Duke

Page 1: ...OWNER S MANUAL 2015 200 Duke 2015 CO Art no 3213118en ...

Page 2: ......

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

Page 4: ...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 AG 5230 Mattighofen Austria ...

Page 5: ...ber 21 6 CONTROLS 22 6 1 Clutch lever 22 6 2 Hand brake lever 22 6 3 Throttle grip 23 6 4 Horn button 23 6 5 Light switch 24 6 6 High beam flasher button 24 6 7 Turn signal switch 25 6 8 Emergency OFF switch 25 6 9 Electric starter button 26 6 10 Ignition steering lock 26 6 11 Combination instrument 27 6 11 1 Overview 27 6 11 2 Activation and test 28 6 11 3 Warning notes 29 6 11 4 Function buttons...

Page 6: ...67 8 8 Refueling 68 9 SERVICE SCHEDULE 70 9 1 Service schedule 70 10 TUNING THE CHASSIS 72 10 1 Adjusting the spring preload of the shock absorber x 72 10 2 Adjusting the shift lever 73 11 SERVICE WORK ON THE CHASSIS 74 11 1 Raising the motorcycle with the rear wheel stand 74 11 2 Taking the motorcycle off of the rear wheel stand 74 11 3 Raising the motorcycle with the front wheel stand 75 11 4 Ta...

Page 7: ... light bulb 120 14 7 Checking the headlight setting 124 14 8 Adjusting the headlight range 125 15 COOLING SYSTEM 128 15 1 Cooling system 128 15 2 Checking the antifreeze and coolant level 129 15 3 Checking the coolant level 131 15 4 Draining the coolant x 133 15 5 Filling bleeding the cooling system x 134 16 TUNING THE ENGINE 136 16 1 Checking the play in the throttle cable 136 16 2 Adjusting the ...

Page 8: ...LE OF CONTENTS 6 21 5 Electrical system 158 21 6 Tires 159 21 7 Fork 159 21 8 Shock absorber 159 21 9 Chassis tightening torques 160 22 SUBSTANCES 164 23 AUXILIARY SUBSTANCES 167 24 STANDARDS 169 INDEX 170 ...

Page 9: ...rstanding In the interest of your own safety have these jobs performed by an authorized KTM workshop There your motorcycle will be optimally cared for by specially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page 1 2 Formats used The typographical formats used in this document are explained below Specific name Identif...

Page 10: ... version only 2 2 Safety advice A number of safety instructions need to be followed to operate the vehicle safely Therefore read this manual carefully The safety instruc tions are highlighted in the text and are referred to at the relevant passages Info The vehicle has various information and warning labels at prominent locations Do not remove information warning labels If they are missing you or ...

Page 11: ...en Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken 2 4 Tampering warning Tampering with the noise control system is prohibited Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design...

Page 12: ... may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch hot components such as exhaust system radiator engine shock absorber and t...

Page 13: ...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 and wear Change damaged or worn parts After you complete the repair or service work check the operating safety of the vehicle 2 8 Environment If you use your motorcycle responsibly you can ensure that p...

Page 14: ...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 needed If you would like to know more about the vehicle or have questions on the material you read please contact an authorized KTM dealer The Owner s Manual is an important component of the vehicle ...

Page 15: ...and auxiliary substances such as fuel and lubricants as specified in the Owner s Manual 3 3 Spare parts accessories For your own safety only use spare parts and accessory products that are approved and or recommended by KTM and have them installed by an authorized KTM workshop KTM accepts no liability for other products and any resulting damage or loss Certain spare parts and accessory products ar...

Page 16: ... observe these exactly you will ensure a much longer service life for your motorcycle 3 5 Figures The figures contained in the manual may depict special equipment In the interest of clarity some components may be shown disassembled or may not be shown at all It is not always necessary to disassem ble the component to perform the activity in question Please follow the instructions in the text 3 6 C...

Page 17: ...15 ...

Page 18: ...4 VIEW OF VEHICLE 16 4 1 View of vehicle front left example B00778 10 ...

Page 19: ...VEHICLE 17 1 Function buttons p 32 1 Indicator lamps p 33 2 Rear mirror 3 Clutch lever p 22 4 Seat 5 Passenger seat 6 Seat lock p 50 7 Grab handles p 51 8 Engine number p 20 9 Side stand p 54 10 Shift lever p 52 ...

Page 20: ...4 VIEW OF VEHICLE 18 4 2 View of vehicle rear right example B00779 10 ...

Page 21: ...asher button p 24 2 Turn signal switch p 25 2 Horn button p 23 3 Filler cap 4 Ignition steering lock p 26 5 Emergency OFF switch p 25 6 Hand brake lever p 22 7 Electric starter button p 26 8 Chassis number type label p 20 9 Passenger footrests p 52 10 Foot brake lever p 53 ...

Page 22: ...0699 10 The chassis number is stamped on the right of the steering head The type label is on the right of the frame behind the steering head 5 2 Engine number B00700 10 The engine number is stamped on the left side of the engine under the engine sprocket ...

Page 23: ...5 SERIAL NUMBERS 21 5 3 Key number B00755 10 The key 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 ...

Page 24: ...lever M00001 10 The clutch lever is fitted on the left side of the handlebar 6 2 Hand brake lever B00702 10 The hand brake lever is fitted on the right side of the handlebar The front brake is engaged using the hand brake lever ...

Page 25: ...hrottle grip is fitted on the right side of the handlebar 6 4 Horn button M00002 10 The horn button is fitted on the left side of the handlebar Possible states Horn button in neutral position Horn button pressed The horn is operated in this position ...

Page 26: ...il light are switched on High beam on Light switch is turned upward In this position the high beam and the tail light are switched on 6 6 High beam flasher button M00004 10 The high beam flasher button is fitted on the left side of the handlebar Possible states High beam flasher button in neutral position High beam flasher button pressed In this position the headlight flasher high beam is actuated...

Page 27: ...o the right The turn signal switch returns automatically to the central position after use To switch off the turn signal press the turn signal switch towards the switch case 6 8 Emergency OFF switch B00707 10 The emergency OFF switch is fitted on the right side of the handlebar Possible states Emergency OFF switch off In this position the ignition circuit is interrupted a running engine stops and ...

Page 28: ...steering lock B00709 01 The ignition steering lock is in front of the upper triple clamp Possible states Ignition OFF In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start The ignition key can be removed Ignition ON In this position the ignition circuit is closed and the engine can be started Steering locked In this position the ignitio...

Page 29: ...6 CONTROLS 27 6 11 Combination instrument 6 11 1 Overview 401685 10 1 Display p 34 2 Function buttons p 32 3 Info display p 38 4 Indicator lamps p 33 ...

Page 30: ...witched on Test The segments of the tachometer and the gear display light up and switch off in sequence The speed display counts from 0 to 199 and back The remaining display segments outside the info display light up briefly The READY TO RACE logo appears on the info display The display then changes to the last selected mode ...

Page 31: ...OLS 29 6 11 3 Warning notes 401309 01 Low Oil Pressure appears on the info display if the oil pressure is too low 401310 01 Low Fuel Level appears on the info display if the fuel level reaches the reserve mark ...

Page 32: ... temperature rises above the specified value Coolant temperature 125 C 257 F 401312 01 Side Stand Down appears on the info display if the side stand is folded down 401313 01 Low Battery appears on the info display if the battery voltage falls below the specified value Battery voltage 10 80 V ...

Page 33: ...Not Reset appears on the info display for 10 seconds when the ignition is switched on and the distance interval between service appointments has been exceeded or the service interval display was not reset during a service appointment ...

Page 34: ...play modes are total distance traveled TRIP 1 distance 1 ODO and distance 2 TRIP 2 Pressing and holding the SET button resets the distance 1 TRIP 1 and distance 2 TRIP 2 functions to 0 0 and briefly pressing the SET button changes the info display to the next display mode Option Without ABS Button has no function ...

Page 35: ...itical error The shift warning lights up flashes red The set shift speed has been reached The idling speed indicator lamp lights up green The transmission is shifted to idle The high beam indicator lamp lights up blue The high beam is switched on The immobilizer indicator lamp lights up or flashes red Status or error message for immobilizer alarm system OPTIONAL The general warning lamp lights up ...

Page 36: ...minute The gear display shows the engaged gear The coolant temperature appears in segment The time appears in segment The filling level in the fuel tank is displaced in segment The info display shows additional information Info After reconnecting the battery or changing the fuse the time must be reset The intensity of the LED display depends on the ambient brightness ...

Page 37: ...6 CONTROLS 35 6 11 7 Filling level display in fuel tank 401292 01 The filling level display consists of 9 bars The more bars are lit the more fuel is in the fuel tank ...

Page 38: ...reserve mark the display mode automatically changes to TRIP F and starts to count from 0 0 regardless of the previous display mode Info At the same time as the display mode TRIP F the general warning lamp lights up and the warning note Low Fuel Level appears on the info display ...

Page 39: ... 13 bars The more bars that light up the hotter the coolant When all bars light up the following warning note appears on the info display High Coolant Temperature Possible states Engine cold Up to three bars light up Engine warm Four to ten bars light up Engine hot Eleven to thirteen bars light up ...

Page 40: ...6 CONTROLS 38 6 11 10 Info display 401291 10 Various warning notes appear on info display If the general warning lamp lights up the corresponding warning note is shown on the info display ...

Page 41: ...u Info If the ignition was switched off for over 60 minutes the display is reset to 0 Press the SET button briefly Next display mode on the info display 6 11 12 Average speed average fuel consumption 1 menu 401465 01 Condition Alternative 1 The ignition is on The motorcycle is stationary Alternative 2 The ignition is on The motorcycle is moving Press the SET button briefly and repeatedly until the...

Page 42: ...ignition is on The motorcycle is stationary Alternative 2 The ignition is on The motorcycle is moving Press the SET button briefly and repeatedly until the desired info display appears In this menu the average fuel consumption 1 in L 100 km or L 100 miles and the aver age fuel consumption 2 in km L or miles L are displayed Info The average fuel consumptions 1 and 2 are displayed after several 100 ...

Page 43: ...ntil the desired info display appears The average fuel consumption 2 in km L or miles L and the distance to the next service are displayed in this menu Info The average fuel consumption 2 is displayed after several 100 meters of travel after the ignition is switched on If the ignition was switched off for over 60 minutes the display of the average fuel consumption 2 is reset to 0 Press the SET but...

Page 44: ...info display appears This menu shows the distance to the next service and the range Info The range depends on the average fuel consumption and the fuel quantity in the fuel tank The range is displayed after several 100 meters of travel after the ignition is switched on If the ignition was switched off for over 60 minutes the display of the range and riding time is reset to 0 Press the SET button b...

Page 45: ...ired info display appears The range and the riding time are displayed in this menu Info The range depends on the average fuel consumption and the fuel quantity in the fuel tank The range is displayed after several 100 meters of travel after the ignition is switched on If the ignition was switched off for over 60 minutes the display of the range and riding time is reset to 0 Press the SET button br...

Page 46: ... even if the battery is disconnected and or the fuse blows Press the MODE but ton Next display mode on the display 6 11 18 Distance menu 1 TRIP 1 401304 01 Condition Alternative 1 The ignition is on The motorcycle is stationary Alternative 2 The ignition is on The motorcycle is moving Press the MODE button briefly and repeatedly until TRIP 1 appears on the display TRIP 1 shows the distance covered...

Page 47: ...torcycle is moving Press the MODE button briefly and repeatedly until TRIP 2 appears on the display TRIP 2 shows the distance covered since the last reset For example the distance from one refueling stop to the next TRIP 2 is always running and counts up to 999 9 Press the SET button for 5 10 seconds Display of TRIP 2 is reset Press the MODE but ton Next display mode on the display 6 11 20 Setting...

Page 48: ...mph to km h 6 11 21 Setting the time Condition The ignition is on The motorcycle is stationary 401303 01 Press the MODE button briefly and repeatedly until ODO appears on the display Press the MODE and SET buttons for 5 10 seconds The time display begins to flash Set the hours display using the MODE button Set the minutes display using the SET button Press the MODE and SET buttons for 5 10 seconds...

Page 49: ...ppears Info The engine speed can be set at intervals of 50 RPM 1 is the engine speed above which the shift warning light starts to flash Set the speed with the MODE and SET buttons Info The MODE button increases the value The SET button decreases the value Do not activate the two buttons for approx 15 seconds The display RPM 1 goes out and the set speed is stored 6 11 23 Adjusting the shift speed ...

Page 50: ...DE and SET buttons Info The MODE button increases the value The SET button decreases the value Do not activate the two buttons for approx 15 seconds The display RPM 2 goes out and the set speed is stored 6 12 Opening the filler cap Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fu...

Page 51: ... clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system B00710 10 Lift the cover of the filler cap and insert the ignition key in the lock Note Danger of damage Ignition key break...

Page 52: ...e 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 and water Close the filler cap Push down the filler cap until the lock engages 6 14 Seat lock B00712 01 The seat lock is located to the left of the seat It can be locked with the ignition key ...

Page 53: ...00758 10 The tool set is located under the passenger seat 6 16 Grab handles B00717 10 The grab handles are used for moving the motorcycle around If you carry a passenger the passenger can hold onto the grab handles during the trip ...

Page 54: ...er footrests can be folded in and out Possible states Passenger footrests folded up For operation without a passenger Passenger footrests folded down For operation with a passenger 6 18 Shift lever B00715 10 Shift lever is mounted on the left side of the engine ...

Page 55: ... can be seen in the photograph The neutral or idle position is between the first and second gears 6 19 Foot brake lever B00718 10 Foot brake lever is located in front of the right footrest The foot brake lever is used to activate the rear brake ...

Page 56: ...e side stand must be folded up during motorcycle use Side stand is coupled with the safety start system see the riding instructions Possible states Side stand folded out The vehicle can be leaned on the side stand The safety start system is active Side stand folded in This position is mandatory for all trips The safety start system is inactive ...

Page 57: ...erent tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Warning Danger...

Page 58: ...making a longer trip Try also to ride as slowly as possible to get a better feel for the vehicle Hold the handlebar firmly with both hands and keep your feet on the footrests when riding Run the engine in p 56 7 2 Running in the engine During the running in phase do not exceed the specified engine speed Guideline Maximum engine speed During the first 1 000 km 620 mi 7 500 rpm Tip During the runnin...

Page 59: ...s Warning Danger of accidents Risk of breakage of suitcase system If you have fitted suitcases on your motorcycle read the manufacturer s specifications concerning the maximum payload Warning Danger of accidents Poor visibility for other road users due to slipped baggage If the tail light is covered you are less visible to traffic behind you especially in the dark Check that your baggage is fixed ...

Page 60: ...of the vehicle and ensure even weight distribu tion between the front and rear wheels Do not exceed the overall maximum permitted weight and the axle loads Guideline Maximum permissible overall weight 335 kg 739 lb Maximum permissible front axle load 125 kg 276 lb Maximum permissible rear axle load 210 kg 463 lb ...

Page 61: ...ke fluid level p 97 Check the front brake linings p 94 Check the rear brake linings p 99 Check the brake system function Check the coolant level p 131 Check for chain dirt accumulation p 80 Check the chain tension p 81 Check the tire condition p 108 Check the tire air pressure p 109 Check the settings of all controls and ensure that they can be operated smoothly Check the functioning of the electr...

Page 62: ...icle is operated with a discharged battery or without a battery electronic components and safety equipment may be damaged Never operate the vehicle with a discharged battery or without a battery Note Engine failure 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 dirt will enter the engine and lead to increase...

Page 63: ... starting DO NOT open the throttle If you open the throttle during the start ing procedure fuel is not injected by the engine management system and the engine cannot start Press the starter for a maximum of 5 seconds Wait for a least 5 seconds before trying again This motorcycle is equipped with a safety starting system You can only start the engine if the transmission is in neutral or if the clut...

Page 64: ...ect ignition key position Do not change the ignition key position during a journey Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle Make all adjustments when the vehicle is at a standstill Warning Risk of injury Falling off of the passenger The passenger must be seated properly on the passenger seat and hold on to the front rider or the grab handles The f...

Page 65: ...not achieved until the tires have been run in Warning Danger of accidents Unstable handling characteristics due to slipped baggage Check the way your baggage is fixed regularly Warning Danger of accidents Lack of roadworthiness After a fall check the vehicle as usual before preparing for use Note Engine failure Overheating of engine If the coolant temperature warning lamp lights up stop and switch...

Page 66: ...s do not shift and accelerate very carefully To shift down brake if necessary and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Switch off the engine if you expect to be standing for a long time If the engine diagnosis warning lamp lights up during a trip stop immediately switch off the eng...

Page 67: ... order to restore the normal braking efficiency you will need to remove the deposits from the discs by carefully applying the brakes Option Without ABS Warning Danger of accidents If you brake too hard the wheels can lock Adapt your braking to the traffic situation and the road conditions When braking release the throttle and apply the front and rear brakes at the same time On sandy wet or slipper...

Page 68: ...rting work on them Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Note Fire hazard Some vehicle components become very hot when the vehicle is operated Do not park the vehicle near flammable or explosive substances Do not place objects on the vehicle while it is still warm from being run Always let the vehicle cool first Note...

Page 69: ...your foot as far as it will go and lean the vehicle on it Lock the steering by turning the handlebar fully to the left pressing down the ignition key to position and turning it to position To make the steering lock engage more easily move the handlebar a little to the left and right Remove the ignition key 8 7 Transport Note Danger of damage The parked vehicle may roll away or fall over Always pla...

Page 70: ...erfilled Follow 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 contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physic...

Page 71: ...danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system B00719 10 Switch off the engine Open the filler cap p 48 Fill the fuel tank with fuel up to the lower edge of the fuel filler Total fuel tank capacity approx 10 5 l 2 77 US gal Super unleaded ROZ 95 RON 95 PON 91 p 166 Close the filler cap p 50 ...

Page 72: ...the brake discs p 91 Check the brake lines for damage and leakage Check the rear brake fluid level p 97 Check the shock absorber and fork for leaks Check the swingarm bearing x Check the wheel bearing for play x Check the tire condition p 108 Check the tire air pressure p 109 Check the chain rear sprocket and engine sprocket p 85 Check the chain tension p 81 Grease all moving parts e g side stand ...

Page 73: ... that the throttle cables are undamaged routed without sharp bends and set correctly x Change the air filter Clean the air filter box x Check the screws and nuts for tightness x Change the front brake fluid x Change the rear brake fluid x Check the headlight setting p 124 Check that the radiator fan is functioning properly x Final check Check the vehicle for roadworthiness and take a test ride Rea...

Page 74: ...he spring preload defines the initial situation of the spring process on the shock absorber The best spring preload setting is achieved when it is set for the weight of the rider and that of any baggage and a passenger thus ensuring an ideal compromise between maneuverability and stability B01419 10 Turn adjusting ring to adjust the spring preload Guideline Spring preload Standard 3 clicks Full pa...

Page 75: ...same adjustments on both sides At least five screw threads must be screwed into the seating Check adjusting angle Guideline Adjusting angle shift rod deflector shift lever 90 Tighten nuts Info After the nuts have been tightened the bearings of the shift rod must be cen trally and identically aligned to each other in order to ensure freedom of move ment in the bearing shells Check the shift lever t...

Page 76: ...e wheel stand Insert the adapter in the rear wheel stand Bushing kit for lifting gear 90229955044 Universal V adapter 61029955244 Rear wheel stand 61029055400 Stand the motorcycle upright align the lifting gear with the swingarm and the adapters and lift the motorcycle 11 2 Taking the motorcycle off of the rear wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always ...

Page 77: ...cle on the side stand Remove the support of the wheel stand 11 3 Raising the motorcycle with the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Preparatory work Raise the motorcycle with the rear wheel stand p 74 M00005 10 Condition Remove cap ...

Page 78: ...wheel stand 61029055500 Info Always raise the rear of the motorcycle first Raise the front of the motorcycle 11 4 Taking the motorcycle off of the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface B01388 01 Secure the motorcycle against falling over Remove the front wheel stand ...

Page 79: ...00005 10 Mount cap 11 5 Removing the passenger seat B00712 01 Insert the ignition key in seat lock and turn it clockwise Raise the rear of the seat push it towards the rear and remove it upwards Remove the ignition key from the seat lock ...

Page 80: ... place Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly After mounting the passenger seat check that it is locked correctly by pulling up Finally check that the passenger seat is correctly mounted 11 7 Removing the seat Preparatory work Remove the passenger seat p 77 B00725 10 Main work Remove screws Raise the rear of the seat pull it ...

Page 81: ...THE CHASSIS 79 11 8 Mounting the seat B00727 10 Main work Attach seat recesses at screws and lower at the rear Mount and tighten screws Guideline Screw seat M6 11 Nm 8 1 lbf ft Finishing work Mount the passenger seat p 78 ...

Page 82: ...s reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc sh...

Page 83: ...accidents Danger caused by incorrect chain tension If the chain is too taut the components of the secondary power transmission chain engine sprocket rear sprocket bearings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme cases If the chain is too loose however i...

Page 84: ...ng guard press the chain upward toward the swingarm and determine chain tension Info The upper chain section must be taut Chain wear is not always even so you should repeat this measurement at differ ent chain positions Chain tension 5 7 mm 0 2 0 28 in If the chain tension does not meet specifications Adjust the chain tension p 83 ...

Page 85: ...ion and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme cases If the chain is too loose however 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 Preparatory work Check...

Page 86: ...e left and right chain adjuster are in the same position in relation to reference marks The rear wheel is then correctly aligned Info The upper chain section must be taut Chain wear is not always even so you should check the setting at different chain positions Tighten nuts Make sure that chain adjusters are fitted correctly on adjusting screws Tighten nut Guideline Nut rear wheel spindle M14x1 5 ...

Page 87: ...procket and engine sprocket 100132 10 Option Without ABS Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the power set x Info The engine sprocket rear sprocket and chain should always be replaced together ...

Page 88: ... chain links in the lower chain section Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance at the longest chain section 301 6 mm 11 874 in If the distance is greater than the specified measurement Change the power set x Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out...

Page 89: ... 10 Check the chain sliding guard for wear If the chain sliding guard has lost material due to wear to the extent that in area drilled hole is visible from above Change the chain sliding guard x Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the chain sliding guard ...

Page 90: ... C00198 10 Position the chain guard and tighten screw Guideline Screw chain guard EJOT PT 4 Nm 3 lbf ft Tighten screw Guideline Screw chain guard EJOT PT 4 Nm 3 lbf ft Tighten screw Guideline Remaining screws chassis M5 5 Nm 3 7 lbf ft ...

Page 91: ...11 SERVICE WORK ON THE CHASSIS 89 11 14 Removing the front spoiler B00770 10 Remove screws B00771 10 Remove screws Take off the front spoiler ...

Page 92: ...g front spoiler B00770 10 Position the front spoiler Mount screws but do not tighten yet B00771 10 Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 93: ...iscs wear limit Front 3 6 mm 0 142 in Rear 3 6 mm 0 142 in If the brake disc thickness is less than the specified value Change the brake discs x Check the front and rear brake discs for damage cracking and deformation If the brake disc shows signs of damage cracking or deformation Change the brake discs x 12 2 Checking the brake fluid level of the front brake Warning Danger of accidents Failure of...

Page 94: ... x p 92 12 3 Adding front brake fluid x Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid cont...

Page 95: ...fluid etc should be disposed of as stipulated in applicable regulations Info Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Preparatory work Check the front brake linings p 94 C00201 10 Main work Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane ...

Page 96: ...braking efficiency caused by 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 the brake linings regularly B00739 10 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change th...

Page 97: ...ail due to over heating Adjust the free travel on foot brake lever according to specifications B00735 10 Disconnect spring Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the free travel of the foot...

Page 98: ...e builds up on the rear brake circuit The rear brake can fail due to over heating Adjust the free travel on foot brake lever according to specifications B00737 10 Disconnect spring Release nut and use screw to adjust the specified free travel Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Info The range of adjustment is limited Hold screw and tighten nut Attach spring ...

Page 99: ...ge the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help C00202 10 Option Without ABS Stand the vehicle upright Check the brake fluid level in the brake fluid reservoir If the fluid level reaches the MIN marking Add rear brake fluid x p 97 12 8 Adding rear brake fluid x Warning Danger of accidents Failure of the brake system...

Page 100: ... Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Avoid contact between...

Page 101: ...g the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help Note Danger of accidents Reduced braking efficiency caused by damaged brake discs If the brake linings are not changed in time the steel brake lining carriers grind on the brake disc The braking effect i...

Page 102: ...linings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings x Check the brake linings for damage and cracking If there is wear or tearing Change the rear brake linings x ...

Page 103: ...Warning Danger of accidents Reduced braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not damaged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork Info Do not pull the hand brake lever when the front wheel is removed Warning Danger of accidents Reduced braking effect caused by damaged brake discs Alw...

Page 104: ...when the front wheel is removed 13 2 Installing the front wheel x 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 ...

Page 105: ...el and insert the wheel spindle The brake linings are correctly positioned Mount and tighten screw Guideline Screw front wheel spindle M8 30 Nm 22 1 lbf ft Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Take the motorcycle off of the front wheel stand p 76 Pull the front brake and push down hard on the fork several t...

Page 106: ...el withdraw wheel spindle with the washer and chain adjuster Push the rear wheel forward as far as possible and take the chain off the rear sprocket Warning Danger of accidents Reduced braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not damaged Pull the rear wheel back and take it out of the swingarm Info Do not operate the foot brake w...

Page 107: ... the rear hub rubber dampers x p 106 B00748 10 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the wheel bearing x Clean and grease the shaft seal rings and mating surfaces of the spacers Long life grease p 167 Clean the thread of the wheel spindle and nut Clean the fixing locations on the brake caliper support and swingarm Install the rubber damper and r...

Page 108: ... correctly aligned the markings on the left and right chain adjusters must be in the same position relative to the reference marks Nut rear wheel spindle M14x1 5 90 Nm 66 4 lbf ft Finishing work Take the motorcycle off of the rear wheel stand p 74 13 5 Checking the rear hub rubber dampers x Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers They even...

Page 109: ...hange all rubber dampers in the rear hub B01550 10 Lay the read wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub To check the play hold the rear wheel tight and try to rotate the rear sprocket Info Measure the play on the outside of the rear sprocket Play in rubber dampers rear wheel 5 mm 0 2 in If play is larger than the specified value Change all...

Page 110: ...rning Danger of accidents Uncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Info The type condition and air pressure of the tires all have a major impact on the riding behavior of the motorcycle Worn tires have a negative effect on riding behavior especially on wet s...

Page 111: ...ecommends that the tires are changed regardless of the actual wear at the latest after 5 years If a tire is more than 5 years old Change the tires 13 7 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life 400695 01 Remove the dust cap Check tire air pressur...

Page 112: ...13 WHEELS TIRES 110 If the tire air pressure does not meet specifications Correct the tire air pressure Mount the dust cap ...

Page 113: ...ttery acid and battery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Preparatory work Remove the passenger seat p 77 Remove the seat p 78 B00750 10 Main work Pull back the negative terminal co...

Page 114: ... motorcycle with a discharged battery or without a battery In both cases electrical components and safety devices can be damaged The vehi cle is therefore no longer roadworthy 14 2 Installing the battery x B00751 11 Main work Position the battery in the battery holder Info The battery terminals must be at the top Attach rubber band Reconnect the positive cable of the battery Position positive term...

Page 115: ...ry Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with wat...

Page 116: ...ging current shortens the battery s service life If the charging current charging voltage and charging time are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over dischar...

Page 117: ...ernator With this device you cannot overcharge the battery Info Never remove lid Charge the battery with a maximum of 10 of the capacity specified on battery housing Switch off the charger after charging Disconnect the battery Guideline The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the motorcycle is not in use 3 months Finishing work Mount...

Page 118: ...onsumers and switch off the engine Remove the passenger seat p 77 B00753 10 Main work Option Without ABS Open fuse box cover B00754 10 Remove the defective fuse Guideline Fuse 1 30 A main fuse Fuse 2 15 A combination instrument Fuse 3 10 A control unit power relay Fuse 4 15 A ignition coil alarm system OPTIONAL Fuse 5 15 A radiator fan Fuse 6 15 A horn brake light turn signal high beam low beam pa...

Page 119: ...ly fuses with the prescribed amperage Never by pass or repair fuses Use spare fuses with the correct rating only Fuse 75011088010 p 158 Fuse 75011088015 p 158 Fuse 75011088030 p 158 Tip Replace the spare fuse in the fuse box so that it is available if needed Check that the power consumer is functioning properly Close the fuse box cover Finishing work Mount the passenger seat p 78 ...

Page 120: ...amp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off all power consumers and switch off the engine 601915 10 Main work Remove expanding rivets 601914 10 Remove screws Lift the headlight mask slightly and swing forward ...

Page 121: ...61 10 Detach retaining clamp Remove headlight bulb Position the new headlight bulb in the headlight housing Headlight H4 socket P43t p 158 Info Insert the headlight bulb so that the catches latch into the recesses Attach retaining clamp B00760 10 Connect plug in connection Mount protection cap ...

Page 122: ...8 1 lbf ft 601915 10 Mount expanding rivets on both sides Check that the lighting is functioning properly 14 6 Changing the parking light 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 it free of grease before mounting ...

Page 123: ...RICAL SYSTEM 121 Preparatory work Switch off all power consumers and switch off the engine 601915 10 Main work Remove expanding rivets 307324 10 Remove screws Lift the headlight mask slightly and swing forward ...

Page 124: ...62 10 Remove screws Take off cover B00763 10 Pull the socket with bulb out of the housing Remove the bulb Position a new light bulb in the socket Parking light W5W socket W2 1x9 5d p 158 Position the socket with bulb in the housing ...

Page 125: ...ion cover Mount and tighten screws 307324 10 Fold the headlight mask up Mount and tighten screws Guideline Screw headlight mask M6 11 Nm 8 1 lbf ft 601915 10 Mount expanding rivets on both sides Check that the lighting is functioning properly ...

Page 126: ...cm 2 in Position the vehicle vertically at a distance in front of the wall and switch on the low beam Guideline Distance 5 m 16 ft The rider with luggage and passenger if applicable now mounts the motorcycle Check the headlight setting The light dark boundary must lie exactly on the lower mark when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if ...

Page 127: ...14 ELECTRICAL SYSTEM 125 14 8 Adjusting the headlight range 601915 10 Main work Remove expanding rivets 601914 10 Remove screws Lift the headlight mask slightly and swing forward ...

Page 128: ...plicable the light dark boundary must be exactly on the lower mark applied in Checking headlight adjustment Info Turn clockwise to increase the headlight range turn counterclockwise to reduce the headlight range 601914 10 Fold the headlight mask up Mount and tighten screws Guideline Screw headlight mask M6 11 Nm 8 1 lbf ft 601915 10 Mount expanding rivets on both sides ...

Page 129: ...14 ELECTRICAL SYSTEM 127 Finishing work Check the headlight setting p 124 ...

Page 130: ...the cooling system is regulated by a valve in radiator cap Heat expansion causes excess coolant to flow into compensating tank When the temperature falls this surplus coolant is sucked back into the cooling system This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions 125 C 257 F ...

Page 131: ...ins also reduce the cooling effect 15 2 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water ...

Page 132: ...ted with coolant Keep coolant out of reach of children Condition The engine is cold B00766 10 Stand the motorcycle upright on a horizontal surface Remove the cap of the compensating tank Check the coolant antifreeze 25 45 C 13 49 F If the coolant antifreeze does not meet specifications Correct the coolant antifreeze Check the coolant level in the compensating tank The coolant level must be between...

Page 133: ...f the loss Alternative 1 Coolant p 164 Alternative 2 Coolant mixed ready to use p 164 If you had to add more coolant than the specified amount 0 20 l 0 21 qt Fill bleed the cooling system x p 134 Mount the radiator cap 15 3 Checking the coolant level Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses ...

Page 134: ... coolant out of reach of children Condition The engine is cold B00766 10 Stand the motorcycle upright on a horizontal surface Check the coolant level in the compensating tank The coolant level must be between MIN and MAX If the coolant level does not meet specifications Correct the coolant level Alternative 1 Coolant p 164 Alternative 2 Coolant mixed ready to use p 164 B01552 10 Remove radiator ca...

Page 135: ...ine is hot Allow the engine and cooling system to cool down In case of scalding 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 with the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap an...

Page 136: ...ng bleeding the cooling system x Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swallowed contact a physician immediately Change clothing that ...

Page 137: ...of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and let it run warm B00766 11 Stop the engine and allow it to cool down When the engine is cool check the coo...

Page 138: ...pecifications Adjust the play in the throttle cable x p 137 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and let it run idle Move the handle...

Page 139: ...00001 11 Check the clutch lever for smooth operation Move the handlebar to the straight ahead position Lightly pull the clutch lever and ascertain the clutch lever play Clutch lever play 1 3 mm 0 04 0 12 in If the clutch lever play does not meet specifications Adjust the clutch cable play x p 138 Note Clutch damage If there is no play on the clutch lever the clutch will begin to slip Before operat...

Page 140: ...utch cable 16 4 Adjusting the clutch cable play x M00007 10 Move the handlebar to the straight ahead position Push back sleeve Loosen lock nut Adjust the play in the clutch level by turning adjusting screw Guideline Clutch lever play 1 3 mm 0 04 0 12 in Tighten lock nut Slide on sleeve ...

Page 141: ...ge of the oil level viewer If the engine oil level is not at the specified level Add the engine oil p 142 17 2 Changing the engine oil and oil filter cleaning the oil screen x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmenta...

Page 142: ...plug with the O ring Remove oil screen with the O ring Completely drain the engine oil Clean the oil drain plug and oil screen thoroughly Position oil screen and mount and tighten oil drain plug with the O ring Guideline Oil drain plug M24x1 5 15 Nm 11 1 lbf ft B00775 10 Remove screws Remove the oil filter cover with the O ring Pull oil filter out of the oil filter housing Circlip pliers reverse 5...

Page 143: ...and fill up with engine oil Engine oil 1 5 l 1 6 qt External temper ature 0 50 C 32 122 F Engine oil SAE 15W 50 p 165 External tempera ture 10 40 C 14 104 F Engine oil SAE 10W 40 p 165 Install and tighten the oil filler plug with the O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there ...

Page 144: ...ngine oil Engine oil SAE 15W 50 p 165 Engine oil SAE 10W 40 p 165 Info For optimal performance of the engine oil do not mix different types of engine oil If appropriate change the engine oil Install and tighten the oil filler plug with O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure ther...

Page 145: ...17 SERVICE WORK ON THE ENGINE 143 Start the engine and check that it is oil tight Finishing work Check the engine oil level p 139 ...

Page 146: ... malfunctions or destroy these parts 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 If you clean the motorcycle regularly its value and appearance will be maintained over a long period Avoid direct sunshine on the motorcycle during cleaning 401061 01 Sea...

Page 147: ...due to a wet or dirty brake sys tem Clean or dry a dirty or wet brake system by riding and braking gently After cleaning ride the vehicle a short distance until the engine warms up Info The heat produced causes water at inaccessible locations in the engine and on the brake system to evaporate Push back the sleeves of the handlebar controls to allow any water that has penetrated to evaporate After ...

Page 148: ...s for winter operation Info If the motorcycle is used in the winter salt can be expected on the roads Precautions need to be taken against road salt corrosion If the vehicle was operated in road salt clean it with cold water after riding Warm water would enhance the corrosive effects of salt 401060 01 Clean the motorcycle p 144 Clean the brakes Info After EVERY trip on salted roads thoroughly wash...

Page 149: ...all other bright and zinc plated parts except for the brake discs with a wax based corrosion inhibitor Info Corrosion inhibitor is not permitted to come in contact with the brake discs as this would greatly reduce the braking force Clean the chain p 80 ...

Page 150: ... 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 167 Refuel p 68 Clean the motorcycle p 144 Change the engine oil and oil filter clean the oil screen x p 139 Check the antifreeze and coolant level p 129 Check the tire air pressure p 109 Remove the battery x p 111 Recharge the battery x p 113 Guideline Storage temperature of b...

Page 151: ... Avoid running the engine for a short time only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 19 2 Preparing for use after storage 401059 01 Take the motorcycle off of the front wheel stand p 76 Take the motorcycle off of the rear wheel stand p 74 Recharge the battery x p 113 Install the battery x p 112 Se...

Page 152: ...ot start Operating error Go through the steps of starting the engine p 60 Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x Engine has too little power Air filter is very dirty Change the air filter Fuel filter is very dirty Check the fuel pressure x Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x Engine overheat...

Page 153: ...sity Change the engine oil and oil filter clean the oil screen x p 139 Headlight and parking light are not functioning Fuse 6 blown Change the fuses of individual power consumers p 116 Turn signal brake light and horn are not functional Fuse 6 blown Change the fuses of individual power consumers p 116 Time is not correctly displayed Fuse 2 blown Option Without ABS Change the fuses of individual po...

Page 154: ...OTING 152 Faults Possible cause Action Speedometer in combination instru ment not functioning Speedometer wiring harness is dam aged or plug in connection is oxidized Check the wiring harness and plug in connection ...

Page 155: ... intake cold 0 08 0 12 mm 0 0031 0 0047 in Valve clearance exhaust cold 0 13 0 17 mm 0 0051 0 0067 in Crankshaft bearing Two ball bearings Conrod bearing Sleeve bearing Pistons Cast light alloy Piston rings 1 L ring 1 tapered compression piston ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with one rotary pump Primary transmission 22 72 Clutch Clutch in oil bath mecha...

Page 156: ...ng permanent circulation of coolant by water pump Idle speed 1 450 1 550 rpm Starting aid Electric starter 21 2 Engine tightening torques Oil nozzle M5 6 Nm 4 4 lbf ft Loctite 243 Screw engine vent plate M5 7 Nm 5 2 lbf ft Loctite 243 Screw oil filter cover M5 8 Nm 5 9 lbf ft Screw retaining bracket M5 6 Nm 4 4 lbf ft Loctite 243 Screw retaining bracket stator cable M5 8 Nm 5 9 lbf ft Loctite 243 ...

Page 157: ... 9 lbf ft Loctite 243 Screw retaining bracket shaft seal ring clutch cover M6 11 Nm 8 1 lbf ft Loctite 243 Screw shift drum locating M6 12 Nm 8 9 lbf ft Loctite 243 Screw starter motor M6 12 Nm 8 9 lbf ft Screw timing chain tensioner M6 12 Nm 8 9 lbf ft Screw timing chain tensioning rail M6 12 Nm 8 9 lbf ft Loctite 243 Screw valve cover M6 12 Nm 8 9 lbf ft Screw water pump cover M6 12 Nm 8 9 lbf f...

Page 158: ... 15 Nm 11 1 lbf ft Nut inner clutch hub M14LH 60 Nm 44 3 lbf ft Loctite 243 Nut primary gear M14 55 Nm 40 6 lbf ft Nut timing chain sprocket M14 55 Nm 40 6 lbf ft Loctite 243 Oil drain plug M24x1 5 15 Nm 11 1 lbf ft 21 3 Capacities 21 3 1 Engine oil Engine oil 1 5 l 1 6 qt External temperature 0 50 C 32 122 F Engine oil SAE 15W 50 p 165 External temperature 10 40 C 14 104 F Engine oil SAE 10W 40 p...

Page 159: ...WP Suspension Shock absorber WP Suspension Brake system Front Disc brake with four pot brake caliper Rear Disc brake with single piston brake caliper floating Suspension travel Front 150 mm 5 91 in Rear 150 mm 5 91 in Brake discs diameter Option Without ABS Front 280 mm 11 02 in Rear 230 mm 9 06 in Brake discs wear limit Front 3 6 mm 0 142 in Rear 3 6 mm 0 142 in Tire air pressure solo Front 2 0 b...

Page 160: ...ound clearance unloaded 170 mm 6 69 in Weight without fuel approx 125 Duke 129 5 kg 285 5 lb Weight without fuel approx 200 Duke without ABS 131 kg 289 lb 21 5 Electrical system Battery FTZ 9 Battery voltage 12 V Nominal capacity 8 Ah Maintenance free Fuse 75011088010 10 A Fuse 75011088015 15 A Fuse 75011088030 30 A Headlight H4 socket P43t 12 V 60 55 W Parking light W5W socket W2 1x9 5d 12 V 5 W ...

Page 161: ...ilable in the Service section under http www ktm com 21 7 Fork Fork part number 90101000044 Fork WP Suspension Fork length 736 mm 28 98 in Fork oil 450 ml 15 21 fl oz Fork oil SAE 4 48601166S1 p 166 21 8 Shock absorber Shock absorber part number 90604010000 Shock absorber WP Suspension Spring preload Standard 3 clicks Full payload 6 clicks Static sag 15 mm 0 59 in Riding sag 45 50 mm 1 77 1 97 in ...

Page 162: ...ine holder rear M5 8 Nm 5 9 lbf ft Loctite 243 Screw fuel pump M5 5 Nm 3 7 lbf ft Screw fuel tank closure flange M5 3 Nm 2 2 lbf ft Screw fuel tank cover M5 4 Nm 3 lbf ft Screw fuel tank trim M5 5 Nm 3 7 lbf ft Screw license plate holder M5 11 Nm 8 1 lbf ft Screw rollover sensor M5 6 Nm 4 4 lbf ft Loctite 243 Screw side stand switch M5 5 Nm 3 7 lbf ft Loctite 243 Screw spoiler M5 5 Nm 3 7 lbf ft S...

Page 163: ...ing M6 5 Nm 3 7 lbf ft Screw fuel tank M6 11 Nm 8 1 lbf ft Screw headlight holder M6 11 Nm 8 1 lbf ft Screw headlight mask M6 11 Nm 8 1 lbf ft Screw ignition coil M6 9 Nm 6 6 lbf ft Screw license plate holder M6 14 Nm 10 3 lbf ft Screw magnetic holder on side stand M6 5 Nm 3 7 lbf ft Loctite 243 Screw radiator bracket M6 6 Nm 4 4 lbf ft Screw radiator holder M6 9 Nm 6 6 lbf ft Screw rear splash pr...

Page 164: ... Loctite 243 Screw rear footrest bracket M8 26 Nm 19 2 lbf ft Loctite 243 Screw shift lever M8 15 Nm 11 1 lbf ft Loctite 243 Screw top triple clamp M8 11 Nm 8 1 lbf ft Screw front brake caliper M8x1 27 Nm 19 9 lbf ft Loctite 243 Fitting side stand M10 34 Nm 25 1 lbf ft Fitting engine mounting bracket M10 55 Nm 40 6 lbf ft Nut mirror M10 16 Nm 11 8 lbf ft Remaining nuts chassis M10 50 Nm 36 9 lbf f...

Page 165: ... wheel spindle M14x1 5 90 Nm 66 4 lbf ft Nut swingarm pivot M14x1 5 100 Nm 73 8 lbf ft Screw top steering head M16x1 5 52 Nm 38 4 lbf ft Swingarm bearing adjusting ring M22x1 Tighten and ensure that there is no play Nut steering head M30x1 Step 1 50 Nm 36 9 lbf ft 2nd stage loosen counter clockwise 2 turns Step 3 5 Nm 3 7 lbf ft ...

Page 166: ...Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant even in countries with high temperatures Using inferior antifreeze can result in corrosion and foaming Use only coolant based on ethylene glycol Mixture ratio Antifreeze protection 25 45 C 13 49 F 50 corrosion inhibitor antifreeze 50 distilled water Coolant mixed ready to use Antifreeze...

Page 167: ...t possess the corresponding properties Partially synthetic engine oil Recommended supplier Motorex Formula 4T Engine oil SAE 10W 40 Standard classification JASO T903 MA p 169 SAE p 169 SAE 10W 40 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Partially synthetic engine oil Recommended supplie...

Page 168: ... possess 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 equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 ...

Page 169: ... Chain Clean Chain lube for road use Guideline Recommended supplier Motorex Chainlube Road Fuel additive Recommended supplier Motorex Fuel Stabilizer Long life grease Recommended supplier Motorex Bike Grease 2000 Motorcycle cleaner Recommended supplier Motorex Moto Clean ...

Page 170: ...rex 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 Recommended supplier Motorex Quick Cleaner Universal oil spray Recommended supplier Motorex Joker 440 Synthetic ...

Page 171: ...rvice intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Stan dard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils...

Page 172: ...99 Brakes 64 Brakes applying 64 C Capacity coolant 156 engine oil 141 156 fuel 69 157 Chain chain dirt accumulation checking 80 checking 85 cleaning 80 Chain tension adjusting 83 checking 81 Chassis number 20 Clutch cable play adjusting 138 Clutch lever 22 Clutch lever play checking 137 Combination instrument activation and test 28 average fuel consumption 1 average fuel consumption 2 menu 40 aver...

Page 173: ...Cooling system 128 filling bleeding 134 Customer service 14 E Electric starter button 26 Emergency OFF switch 25 Engine running in 56 Engine number 20 Engine oil adding 142 changing 139 Engine oil level checking 139 Engine sprocket checking 85 Environment 11 F Figures 14 Filler cap closing 50 opening 48 Filling up fuel 68 Foot brake lever 53 free travel adjusting 96 free travel checking 95 Front s...

Page 174: ... the front wheel stand 75 raising with the rear wheel stand 74 taking off of the front wheel stand 76 taking off of the rear wheel stand 74 O Oil filter changing 139 Oil screen cleaning 139 Operating substances 13 Owner s Manual 12 P Parking 66 Parking light bulb changing 120 Passenger footrests 52 Passenger seat mounting 78 removing 77 Play in throttle cable adjusting 137 checking 136 Preparing f...

Page 175: ...peed RPM 1 adjusting 47 Shift speed RPM 2 adjusting 47 Shifting 62 Shock absorber spring preload adjusting 72 Side stand 54 Spare parts 13 Starting 60 Steering lock 26 Stopping 66 Storage 148 T Technical data capacities 156 chassis 157 chassis tightening torques 160 electrical system 158 engine 153 engine tightening torques 154 fork 159 shock absorber 159 tires 159 Throttle grip 23 Time adjusting ...

Page 176: ...ansport 67 Troubleshooting 150 152 Turn signal switch 25 Type label 20 U Use definition 8 V View of vehicle front left 16 rear right 18 W Warranty 13 Winter operation checks and maintenance steps 146 Work rules 11 ...

Page 177: ... 3213118en 3213118en 03 2014 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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KTM 2015 200 Duke, Owner'S Manual

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Summary of Contents for 2015 200 Duke

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