KTM 2015 RC 390 ASIA Owner'S Manual Download Page 113

Page: 113 / 196

BRAKE SYSTEM

111

M00461-10

–

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 brake lever.

(

p. 111)

–

Reconnect spring



13.10

Adjusting the free travel of the foot brake lever

Warning

Danger of accidents

Brake system failure.

–

If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to over-
heating. Adjust the free travel on foot brake lever according to specifications.

Summary of Contents for 2015 RC 390 ASIA

Page 1: ...OWNER S MANUAL 2015 RC 390 EU RC 390 AU RC 390 JP RC 390 ASIA RC 390 BR RC 390 CN RC 390 MY Art no 3213249en ...

Page 2: ......

Page 3: ...t completely All specifications are non binding KTM Motorrad AG specifically reserves the right to modify or delete technical specifications prices col ors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local condi tions as well as to stop production of a particular model without prior notice KTM accepts no liability for deliver...

Page 4: ...61 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 Motorrad AG 5230 Mattighofen Austria ...

Page 5: ...example 18 5 SERIAL NUMBERS 20 5 1 Chassis number 20 5 2 Type label 20 5 3 Engine number 21 5 4 Key number 21 6 CONTROLS 22 6 1 Clutch lever 22 6 2 Hand brake lever 22 6 3 Throttle grip 23 6 4 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 Locking the steerin...

Page 6: ...reparing for use 60 9 2 Starting 61 9 3 Starting off 63 9 4 Shifting riding 63 9 5 Applying the brakes 66 9 6 Stopping parking 68 9 7 Transport 69 9 8 Refueling 70 10 SERVICE SCHEDULE 72 10 1 Additional information 72 10 2 Required work 72 10 3 Recommended work 74 11 TUNING THE CHASSIS 75 11 1 Adjusting the spring preload of the shock absorber 75 11 2 Adjusting the shift lever 76 12 SERVICE WORK O...

Page 7: ...ber dampers 118 14 6 Checking the tire condition 120 14 7 Checking the tire air pressure 121 15 ELECTRICAL SYSTEM 123 15 1 Removing the battery 123 15 2 Installing the battery 124 15 3 Recharging the battery 125 15 4 Changing the ABS fuses 128 15 5 Changing the fuses of individual power consumers 130 15 6 Changing the low beam bulb 132 15 7 Changing the high beam bulb 133 15 8 Checking the low bea...

Page 8: ... 1 Storage 160 20 2 Preparing for use after storage 161 21 TROUBLESHOOTING 162 22 FLASH CODE 165 23 TECHNICAL DATA 171 23 1 Engine 171 23 2 Engine tightening torques 172 23 3 Capacities 175 23 3 1 Engine oil 175 23 3 2 Coolant 175 23 3 3 Fuel 175 23 4 Chassis 175 23 5 Electrical system 177 23 6 Tires 177 23 7 Fork 178 23 8 Shock absorber 178 23 9 Chassis tightening torques 178 24 SUBSTANCES 184 25...

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: ...n Warning Indicates 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 i...

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

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

Page 17: ...15 ...

Page 18: ...4 VIEW OF VEHICLE 16 4 1 View of vehicle front left example L02250 10 ...

Page 19: ... VIEW OF VEHICLE 17 1 Horn button p 23 1 Light switch p 24 1 High beam flasher button p 24 1 Turn signal switch p 25 2 Clutch lever p 22 3 Filler cap 4 Seat lock p 29 5 Side stand p 33 6 Shift lever p 31 ...

Page 20: ...4 VIEW OF VEHICLE 18 4 2 View of vehicle rear right example L02251 10 ...

Page 21: ... 1 Grab handles p 30 2 Tool set p 30 3 Ignition steering lock p 26 4 Emergency OFF switch p 25 4 Electric starter button p 26 5 Throttle grip p 23 6 Hand brake lever p 22 7 Passenger footrests p 31 8 Foot brake lever p 32 ...

Page 22: ...BERS 20 5 1 Chassis number 402175 10 The chassis number is stamped on the right side of the frame under the seat 5 2 Type label 0 0 1 1 402174 10 The type label is on the right of the frame behind the steering head ...

Page 23: ...10 The engine number is stamped on the left side of the engine under the engine sprocket 5 4 Key number 402245 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 L02111 10 The clutch lever is fitted on the left side of the handlebar 6 2 Hand brake lever L02112 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 L02113 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: ...are switched on High beam on The light switch is turned upwards In this position the low beam the high beam and the tail light are switched on 6 6 High beam flasher button L02113 12 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...

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 L02114 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 L02115 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: ...e 400732 01 Park the vehicle Turn the handlebar all the way to the left Insert the key into the ignition handlebar lock press in and turn to the left Remove the key Steering is no longer possible 6 12 Unlocking the steering 400731 01 Insert the key into the ignition handlebar lock press in and turn to the right Remove the key You can now steer the bike again ...

Page 30: ...act 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 physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the environm...

Page 31: ...r 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 and water Close the filler cap Push down the filler cap until the lock engages 6 15 Seat lock M00454 10 The seat lock is located to the left of the seat It can be locked with the ignition key ...

Page 32: ...4 10 The tool set is in the storage compartment under the seat 6 17 Grab handles L02256 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 33: ...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 19 Shift lever 401950 10 Shift lever is mounted on the left side of the engine ...

Page 34: ... can be seen in the photograph The neutral or idle position is between the first and second gears 6 20 Foot brake lever 402177 10 Foot brake lever is located in front of the right footrest The foot brake lever is used to activate the rear brake ...

Page 35: ...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 36: ...7 COMBINATION INSTRUMENT 34 7 1 Overview 401685 10 1 Display p 41 2 Function buttons p 39 3 Info display p 45 4 Indicator lamps p 40 ...

Page 37: ... is switched 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 38: ... INSTRUMENT 36 7 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 39: ...coolant 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 40: ...ervice 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 41: ...le display 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 The ABS can be switched off using button ...

Page 42: ... 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 yellow An operating safety warning message was d...

Page 43: ...s per 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 44: ...7 COMBINATION INSTRUMENT 42 7 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 45: ...o the 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 46: ...ts of 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 47: ...7 COMBINATION INSTRUMENT 45 7 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 48: ...s The riding time and average speed are displayed in this menu 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 7 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 mo...

Page 49: ...age fuel consumption 1 average fuel consumption 2 menu 401466 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 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 mile...

Page 50: ...the SET button briefly and repeatedly until 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 consum...

Page 51: ...sired 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 bu...

Page 52: ...he desired 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 but...

Page 53: ...O appears on the display ODO shows the total distance covered Info This value is retained even if the battery is disconnected and or the fuse blows Press the MODE but ton Next display mode on the display 7 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 briefl...

Page 54: ...ance menu 2 TRIP 2 401305 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 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 99...

Page 55: ...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 button for 5 10 seconds The display changes from km h to mph or from mph to km h 7 21 Setting the time Condition The ignition is on The motorcycle is stationary ...

Page 56: ... 22 Adjusting the shift speed RPM 1 Condition The ignition is on The motorcycle is stationary 401307 01 Press the MODE button briefly and repeatedly until TRIP 2 appears on the display Press the MODE button for 5 10 seconds The display RPM 1 appears 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 t...

Page 57: ...e SET button for 5 10 seconds The display RPM 2 appears Info The engine speed can be set at intervals of 50 RPM 2 is the engine speed above which the shift warning light lights up con stantly The speed RPM 2 must always be higher than the speed RPM 1 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 butto...

Page 58: ...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 59: ...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 57 8 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 60: ...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 61: ...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 62: ...l p 107 Check the front brake linings p 106 Check the rear brake linings p 109 Check the brake system function Check the coolant level in the compensating tank p 139 Check for chain dirt accumulation p 84 Check the chain tension p 85 Check the tire condition p 120 Check the tire air pressure p 121 Check the settings of all controls and ensure that they can be operated smoothly Check the functionin...

Page 63: ...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 64: ... back out after starting off Press the electric starter button Info Do not press the electric starter button until the combination instrument func tion check is finished When starting DO NOT open 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 ...

Page 65: ...neously open the throttle carefully Tip If the engine dies while starting off only pull the clutch lever and press the electric starter button You do not need to shift into neutral 9 4 Shifting riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control Avoid abrupt load alterations and sudden braking actions and adapt your speed to the road conditions Wa...

Page 66: ...g 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 danger early on Warning Danger of accidents Reduced road grip with cold tires On every journey take the first miles carefully at moderate speed until the tires reach operating temperature and optimal ...

Page 67: ...ue with the coolant temperature warning lamp alight you may have engine failure Info If you hear unusual noises while riding stop immediately switch off the engine and contact an authorized KTM workshop 401950 11 When conditions allow incline road situation etc you can shift into a higher gear Release the throttle while simultaneously pulling the clutch lever shift into the next gear release the c...

Page 68: ...g the brakes Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a dirty or wet brake system by riding and braking gently Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of...

Page 69: ...ABS is active you can achieve maximum braking power even on low grip surfaces such as sandy wet or slippery terrain without locking of the wheels Warning Danger of accidents Locking of the wheels due to braking action of the engine Pull the clutch during emergency braking full brake application and when braking on a slippery surface Warning Danger of accidents Road grip is reduced when braking wit...

Page 70: ...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 71: ...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 9 7 Transport Note Danger of damage The parked vehicle may roll away or fall over Always pla...

Page 72: ...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 73: ...a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system L02129 10 Switch off the engine Open the filler cap p 28 Fill the fuel tank with fuel up to the lower edge of the fuel filler Total fuel tank capacity approx 10 l 2 6 US gal Super unleaded ROZ 95 RON 95 PON 91 p 185 Close the filler cap p 29 ...

Page 74: ...nt Change the engine oil and oil filter and clean the oil screens p 151 Check the brake discs p 103 Check the front brake linings p 106 Check the rear brake linings p 109 Check the tire condition p 120 Check the tire air pressure p 121 Check the brake lines for damage and leakage Check the brake fluid level of the front brake p 104 Check the rear brake fluid level p 107 Check the shock absorber an...

Page 75: ...e valve clearance change the spark plugs Change the front brake fluid Change the rear brake fluid Check the steering head bearing play Check the low beam headlight adjustment p 135 Check the high beam headlight adjustment p 136 Check that the throttle cables are undamaged routed without sharp bends and set correctly Final check Check the vehicle for roadworthiness and take a test ride Read out the...

Page 76: ... bearings Grease all moving parts e g side stand hand lever chain and check for smooth operation Empty the drainage hoses RC 390 BR RC 390 CN Check all hoses e g fuel cooling bleeder drainage etc and sleeves for cracking leaks and correct routing Check the antifreeze Check the screws and nuts for tightness Change the coolant One time interval Periodic interval ...

Page 77: ... 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 L02252 10 Set the spring preload by turning adjusting ring using the hook wrench from the tool set Guideline Spring preload Comfort 3 clicks Standard 5 clic...

Page 78: ...nut holding the threaded rod Adjust the shift lever by turning shift rod Guideline Shift rod adjustment range 150 162 mm 5 91 6 38 in Info Make the same adjustments on both sides At least five screw threads must be screwed into the seating Check adjusting angle Guideline Adjusting angle shift rod linkage shift lever 75 Tighten nut holding the threaded rod Guideline Nut shift rod M6 10 Nm 7 4 lbf f...

Page 79: ...11 TUNING THE CHASSIS 77 Tighten nut holding the threaded rod Guideline Nut shift rod M6LH 10 Nm 7 4 lbf ft Check the shift lever to ensure it is functioning properly and can move freely ...

Page 80: ...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 12 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 81: ...lean the vehicle on the side stand 12 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 78 M00453 10 Condition Remove protection cap ...

Page 82: ...29055500 Info Always raise the rear of the motorcycle first Raise the front of the motorcycle 12 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 L02254 01 Main work Secure the motorcycle against falling over Remove the front wheel stand ...

Page 83: ...e the motorcycle off of the rear wheel stand p 78 12 5 Removing the front rider s seat M00454 10 Insert the ignition key in seat lock and turn it clockwise Raise the rear of the front rider s seat pull it toward the rear and remove it upward Remove the ignition key from the seat lock ...

Page 84: ... the fuel tank push the front rider s seat forward and lower at the rear Catch engages in the recess Check that the front rider s seat is correctly mounted 12 7 Removing the passenger seat Preparatory work Remove the front rider s seat p 81 L02191 10 Main work Remove screw with the washer Lift and take off the passenger seat ...

Page 85: ...tighten screw with the washer Guideline Screw passenger seat M6 7 Nm 5 2 lbf ft 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 Check that the passenger seat is correctly mounted Finishing work Mount the front rider s seat p 82 ...

Page 86: ...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 87: ...rear wheel stand p 78 12 11 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain is too taut the components of the secondary power transmission chain engine sprocket rear sprocket bearings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the t...

Page 88: ...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 87 ...

Page 89: ...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 90: ... that the markings on the left and right chain adjusters 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 re...

Page 91: ...hain rear sprocket and engine sprocket 100132 10 Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the power set Info The engine sprocket rear sprocket and chain should always be replaced together ...

Page 92: ... 20 chain links in the lower chain section Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance at the longest chain section 301 6 mm 11 874 in If distance is greater than the specified measurement Change the power set Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out f...

Page 93: ...iding guard has lost material due to wear to the extent that in area the drilled hole of screw is visible from above Change the chain sliding guard Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten the chain sliding guard 12 14 Removing the battery cover Preparatory work Remove the front rider s seat p 81 ...

Page 94: ...12 SERVICE WORK ON THE CHASSIS 92 M00450 10 Main work Pull loop toward the rear Pull battery cover forward and remove toward the top ...

Page 95: ...d pull toward the rear The battery cover engages with an audible click Check the battery cover is seated correctly Finishing work Mount the front rider s seat p 82 12 16 Removing the front spoiler Preparatory work Remove the right side cover p 100 Remove the left side cover p 97 L02258 10 Main work Remove screws ...

Page 96: ...12 SERVICE WORK ON THE CHASSIS 94 L02257 11 Remove screw L02263 12 Remove screws G01721 13 Remove screw Remove screw Take off the front spoiler ...

Page 97: ...t and tighten screw Guideline Screw front spoiler retaining bracket rear on engine M6 9 Nm 6 6 lbf ft Mount and tighten screw Guideline Screw front spoiler retaining bracket rear on engine M6 9 Nm 6 6 lbf ft L02263 13 Mount and tighten screws Guideline Screw front spoiler retaining bracket rear M6 6 Nm 4 4 lbf ft ...

Page 98: ...tighten screw Guideline Screw front spoiler right on footrest bracket M6 7 Nm 5 2 lbf ft L02258 12 Mount and tighten screws Guideline Screw front spoiler M6 7 Nm 5 2 lbf ft Finishing work Install the left side cover p 98 Install the right side cover p 101 ...

Page 99: ...12 SERVICE WORK ON THE CHASSIS 97 12 18 Removing the left side cover L02268 10 Remove screws Remove screws Pull off holding lug in area M00456 10 Remove expanding rivet ...

Page 100: ...12 SERVICE WORK ON THE CHASSIS 98 L02260 10 Swing the side cover outward Pull hose out of hose guide Take off the side cover 12 19 Installing the left side cover L02260 11 Position hose in hose guide ...

Page 101: ...nd tighten screws Guideline Screw side cover M6 7 Nm 5 2 lbf ft Push on the side cover in area The holding lug engages in the drilled hole on the front spoiler Mount and tighten screws Guideline Screw side cover on front mask M6 6 Nm 4 4 lbf ft M00456 11 Mount expanding rivet ...

Page 102: ...12 SERVICE WORK ON THE CHASSIS 100 12 20 Removing the right side cover L02267 10 Remove screws Remove screws Pull off holding lug in area M00455 10 Remove expanding rivet Take off the side cover ...

Page 103: ...e side cover Mount and tighten screws Guideline Screw side cover M6 7 Nm 5 2 lbf ft Push on the side cover in area The holding lug engages in the drilled hole on the front spoiler Mount and tighten screws Guideline Screw side cover on front mask M6 6 Nm 4 4 lbf ft M00455 10 Mount expanding rivet ...

Page 104: ...mended by KTM Service work and repairs must be performed properly Your authorized KTM workshop will be glad to help The ABS is a safety system that prevents locking of the wheels when the vehicle is traveling straight ahead without the action of lateral forces Warning Danger of accidents Vehicle rollover It is not always possible to prevent vehicle rollover in extreme riding situations e g luggage...

Page 105: ...s causes the ABS to switch off To reenable the ABS the vehicle must be stopped and the ignition switched off The ABS is reenabled when the vehicle is switched on again The ABS warning lamp goes out when you start off Button can be used to switch ABS off manually see Starting 13 2 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc s Change the wor...

Page 106: ...cates 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 Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help L02132 10 Move the brake ...

Page 107: ...gles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause envir...

Page 108: ...r spilt brake fluid immediately with water 13 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 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 lini...

Page 109: ...rear brake fluid level Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid...

Page 110: ...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 contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warni...

Page 111: ... from a sealed container Preparatory work Check the rear brake linings p 109 M00459 10 Main work Stand the vehicle upright Remove screw cap with membrane Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 184 Refit screw cap with membrane Info Clean up overflowed or spilt brake fluid immediately with water 13 8 Checking the rear brake linings Warning Danger of accidents Reduced braking efficienc...

Page 112: ...or minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings Check the brake linings for damage and cracking If there is wear or tearing Change the rear brake linings 13 9 Checking the free travel of foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure build...

Page 113: ... 2 in If the free travel does not meet specifications Adjust the free travel of the foot brake lever p 111 Reconnect spring 13 10 Adjusting the free travel of the foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to over heating Adjust the free travel on foot ...

Page 114: ...1 11 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 115: ... out of the hole Loosen screw and screws Unscrew screw about 6 turns and press your hand on the screw to push the wheel spindle out of the axle clamp Remove screw Warning Danger of accidents Reduced braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not dam aged Holding the front wheel withdraw the wheel spindle Take the front wheel out of...

Page 116: ...eep the brake discs free of oil and grease and clean them with brake cleaner when necessary L02183 11 Main work Remove spacers 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 mating surfaces of the spacers Long life grease p 186 Insert the spacers ...

Page 117: ...w wheel speed sensor holder M6 9 Nm 6 6 lbf ft Loctite 243 Mount and tighten screws 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 80 Pull the front brake and compress the fork forcefully a few times The fork legs straighten Tighten screws Guideline Screw fork stub M...

Page 118: ...ding the rear wheel 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 dam aged Pull the rear wheel back and take it out of the swingarm Info Do not operat...

Page 119: ...essure point is reached Main work Check the rear hub rubber dampers p 118 L02151 10 Remove spacers Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the rear wheel bearing Clean and grease the shaft seal rings and mating surfaces of the spacers Long life grease p 186 Insert the spacers Clean the thread of the wheel spindle and nut Clean the fixing locations...

Page 120: ...sters must be in the same position relative to the reference marks Nut rear wheel spindle M14x1 5 90 Nm 66 4 lbf ft Position wheel speed sensor in the drill hole Mount and tighten screw Guideline Screw wheel speed sensor holder M6 9 Nm 6 6 lbf ft Loctite 243 Finishing work Take the motorcycle off of the rear wheel stand p 78 14 5 Checking the rear hub rubber dampers Info The engine power is transm...

Page 121: ...rn Change all rubber dampers in the rear hub L02152 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...

Page 122: ...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 123: ...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 14 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 124: ...14 WHEELS TIRES 122 If the tire air pressure does not meet specifications Correct the tire air pressure Mount the dust cap ...

Page 125: ...cid 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 front rider s seat p 81 Remove the battery cover p 91 L02156 10 Main work Pull back the negative termi...

Page 126: ...e 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 15 2 Installing the battery L02157 10 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 termi...

Page 127: ... injury 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 wit...

Page 128: ...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 discharged a...

Page 129: ... of the bat tery and to test the alternator With this device you cannot overcharge the battery Info Never remove lid 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 the battery cover p 93 Mount the front rider s s...

Page 130: ... of the ABS The third fuse which protects the ABS control unit is located in the fuse box Preparatory work Switch off all power consumers and the engine Remove the front rider s seat p 81 Remove the battery cover p 91 L02158 10 To change the fuse of the ABS hydraulic unit Take off the protection cap and remove fuse Info A defective fuse is indicated by a burned out fuse wire Warning Fire hazard Th...

Page 131: ...cap and remove fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never bypass or repair fuses Use spare fuses with the correct rating only Fuse 90111088025 p 177 Tip Replace spare fuse in the fuse box so that it is available if needed Mount the protection cap Finishing work Mount the battery cover p 93 Mount the...

Page 132: ...p 81 Remove the battery cover p 91 L02275 10 Main work Open fuse box cover Remove the defective fuse Guideline Fuse 1 30 A main fuse Fuse 2 15 A start auxiliary relay alarm system OPTIONAL Fuse 3 15 A control unit power relay Fuse 4 15 A ignition coil Fuse 5 15 A radiator fan Fuse 6 15 A horn brake light turn signal high beam low beam parking light tail light license plate lamp Fuse 7 10 A combina...

Page 133: ... amperage Never bypass or repair fuses Use spare fuses with the correct rating only Fuse 75011088005 p 177 Fuse 75011088010 p 177 Fuse 75011088015 p 177 Fuse 75011088030 p 177 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 battery cover p 93 Mount the front rider s ...

Page 134: ...p and keep it free of grease before mounting Preparatory work Switch off all power consumers and switch off the engine L02161 10 Main work Turn socket counterclockwise Pull the socket with low beam bulb out of the headlight housing Disconnect the socket with the low beam bulb from connector and remove Connect the new socket with the low beam bulb to the connector Low beam H11 Sockel PGJ19 2 p 177 ...

Page 135: ... that the lighting is functioning properly 15 7 Changing the high beam 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 Preparatory work Switch off all power consumers and switch off the engine ...

Page 136: ... housing Disconnect the socket with the high beam bulb from connector and remove Connect the new socket with the high beam bulb to the connector High beam H11 Sockel PGJ19 2 p 177 L02165 10 Position the socket with the high beam bulb in the headlight housing Turn the socket clockwise Check that the lighting is functioning properly ...

Page 137: ...in Position the vehicle perpendicular to the wall at a distance from 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 low beam headlight adjustment 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 ...

Page 138: ...in Position the vehicle vertically at a distance in front of the wall and switch on the high beam Guideline Distance 5 m 16 ft The rider with luggage and passenger if applicable now mounts the motorcycle Check the high beam headlight adjustment The center of the light cone must lie exactly on the lower mark when the motorcycle is ready to operate with the rider mounted along with any luggage and a...

Page 139: ...n counterclockwise to reduce the headlight range Finishing work Check the low beam headlight adjustment p 135 15 11 Adjusting the headlight range of the high beam L02163 10 Main work Adjust the beam distance of the high beam by turning screw Guideline For a motorcycle with rider and with luggage and a passenger if applicable the light dark boundary must be exactly on the lower mark applied in Chec...

Page 140: ...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 141: ...lso reduce the cooling effect 16 2 Checking the coolant level in the compensating tank 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 142: ...s contaminated with coolant Keep coolant out of reach of children Condition The engine is cold The radiator is completely full M00464 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 there is no coolant in the compensating tank Check the cooling system for leaks Info Do not start up the motorcy...

Page 143: ... 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 is contaminated with coolant Keep coolant out of reach of children Condition The engine is cold Preparatory work Remove the right side cover p 100 M00464 10 Main work ...

Page 144: ...eeze does not meet specifications Correct the coolant antifreeze Check the coolant level in the radiator The radiator must be completely filled If the coolant level does not meet specifications Correct the coolant level and find out the cause of the loss Coolant p 184 If you had to add more coolant than the specified amount 0 20 l 0 21 qt Fill bleed the cooling system p 145 Mount the radiator cap ...

Page 145: ...alth 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 is contaminated with coolant Keep coolant out of reach of children Condition The engine is...

Page 146: ...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 is contaminated with coolant Keep coolant out of reach of children Condition The engine is cold Preparatory work Remove the right side cover p...

Page 147: ... 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 is contaminated with coolant Keep coolant out of reach of children L02266 10 Main work Remove radiator cap ...

Page 148: ...m 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 M00464 11 Stop the engine and allow it to cool down When the engine is cool check the coolant level in the radiator and if necessary add coola...

Page 149: ...16 COOLING SYSTEM 147 Install the right side cover p 101 ...

Page 150: ...specifications Adjust the play in the throttle cable p 149 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and let it run idle Move the handleb...

Page 151: ...he clutch lever for smooth operation Move the handlebar to the straight ahead position Pull the clutch lever until resistance is perceptible and determine the play in the clutch lever 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 p 150 Note Clutch damage If there is no play on the clutch lever the clutch will begin to slip ...

Page 152: ...lutch cable 17 4 Adjusting the clutch cable play L02155 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 153: ...dge of the oil level viewer If the engine oil level is not at the specified level Add the engine oil p 154 18 2 Changing the engine oil and oil filter cleaning the oil screens 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 154: ... Place a suitable container under the engine Remove the oil drain plug with the O ring Remove oil screen with the O ring Remove screw plug with oil screen Completely drain the engine oil Thoroughly clean the oil drain plugs and oil screens 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 Mount and tighten screw plug with oi...

Page 155: ...erse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing area L02271 10 Insert oil filter Lubricate the O ring of the oil filter cover Mount the oil filter cover Mount and tighten the screws Guideline Screw oil filter cover M5 8 Nm 5 9 lbf ft Info Too little engine oil or poor quality engine oil results in premature wear to the engine ...

Page 156: ...ult in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight Finishing work Fit the front spoiler p 95 Install the left side cover p 98 Install the right side cover p 101 Check the engine oil level p 1...

Page 157: ... appropriate change the engine oil 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 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 ...

Page 158: ... 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 159: ...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 160: ...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 156 Clean the brakes Info After EVERY trip on salted roads thoroughly wash...

Page 161: ...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 84 ...

Page 162: ... for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 186 Refuel p 70 Clean the motorcycle p 156 Change the engine oil and oil filter and clean the oil screens p 151 Check the antifreeze and coolant level p 141 Check the tire air pressure p 121 Remove the battery p 123 Recharge the battery p 125 Guideline Storage temperature of battery without direct sunl...

Page 163: ...e for a short time only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 20 2 Preparing for use after storage 401059 01 Take the motorcycle off of the front wheel stand p 80 Take the motorcycle off of the rear wheel stand p 78 Recharge the battery p 125 Install the battery p 124 Set the clock p 53 Perform che...

Page 164: ...t Operating error Go through the steps of starting the engine p 61 Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool Engine has too little power Air filter is very dirty Change the air filter Fuel filter is very dirty Check the fuel pressure Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool Engine overheats Too little ...

Page 165: ...gain Malfunction in ABS Read out the ABS fault memory using the KTM diagnostics tool High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary Engine oil level too high Check the engine oil level p 151 Engine oil too thin low viscosity Change the engine oil and oil filter and clean the oil screens p 151 Headlight and parking light are not functioning Fu...

Page 166: ...ck the open circuit current The combination instrument shows nothing on the display Fuse 7 is blown Change the fuses of individual power consumers p 130 Set the clock p 53 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 167: ...FI warning lamp MIL 09 FI warning lamp MIL flashes 9x short Error level condition Manifold absolute pressure sensor input signal too low Manifold absolute pressure sensor input signal too high Blink code of FI warning lamp MIL 11 FI warning lamp MIL flashes 1x long 1x short Error level condition Idle control engine speed below target value Idle control engine speed above target value Blink code of...

Page 168: ...rcuit fault Fuel tank sensor short circuit to ground Fuel tank sensor short circuit to plus Blink code of FI warning lamp MIL 15 FI warning lamp MIL flashes 1x long 5x short Error level condition Rollover sensor plausibility Rollover sensor circuit fault Rollover sensor short circuit to ground Rollover sensor short circuit to plus Blink code of FI warning lamp MIL 16 FI warning lamp MIL flashes 1x...

Page 169: ...evel condition Engine diagnosis warning lamp MIL circuit fault Engine diagnosis warning lamp MIL short circuit to ground Engine diagnosis warning lamp MIL short circuit to plus Blink code of FI warning lamp MIL 19 FI warning lamp MIL flashes 1x long 9x short Error level condition Fuel pump lamp circuit fault Low fuel warning lamp input signal too low Low fuel warning lamp input signal too high Bli...

Page 170: ... short Error level condition Travel speed sensor measurement range or power problem Blink code of FI warning lamp MIL 24 FI warning lamp MIL flashes 2x long 4x short Error level condition System voltage too low System voltage too high System voltage implausible value Blink code of FI warning lamp MIL 25 FI warning lamp MIL flashes 2x long 5x short Error level condition Side stand switch plausibili...

Page 171: ...level condition Sensor B reference voltage input signal too low Sensor B reference voltage input signal too high Blink code of FI warning lamp MIL 33 FI warning lamp MIL flashes 3x long 3x short Error level condition Injector circuit fault Injector input signal too low Injector input signal too high Blink code of FI warning lamp MIL 41 FI warning lamp MIL flashes 4x long 1x short Error level condi...

Page 172: ...sensor heater circuit fault Lambda sensor heater short circuit to ground or open circuit Lambda sensor heater input signal too high Blink code of FI warning lamp MIL 49 FI warning lamp MIL flashes 4x long 9x short Error level condition Idle control input signal too low Idle control input signal too high Idle control circuit fault ...

Page 173: ... 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 2 slide bearings Conrod bearing Sleeve bearing Pistons Forged light alloy Piston rings 1 compression ring 1 tapered compression piston ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with two rotary pumps Primary transmission 30 80 Clutch Clutch in oi...

Page 174: ... 04 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 650 1 750 rpm Starting aid Electric starter 23 2 Engine tightening torques Oil nozzle M5 6 Nm 4 4 lbf ft Loctite 243 Screw gear sensor M5 6 Nm 4 4 lbf ft Loctite 243 Screw ignition pulse generator M5 6 Nm 4 4 lbf ft Loctite 243 Screw oil filter cover M5 8 Nm 5 9 lbf ft Screw retaining bracket M5 6 Nm 4 4 lbf f...

Page 175: ...ngine case M6x35 12 Nm 8 9 lbf ft Screw engine case M6x75 12 Nm 8 9 lbf ft Screw engine vent plate M6 10 Nm 7 4 lbf ft Loctite 243 Screw freewheel gear retaining bracket M6 12 Nm 8 9 lbf ft Loctite 243 Screw lock washer engine sprocket M6 12 Nm 8 9 lbf ft Loctite 243 Screw locking lever M6 12 Nm 8 9 lbf ft Loctite 243 Screw oil pump M6 12 Nm 8 9 lbf ft Loctite 243 Screw retaining bracket shaft sea...

Page 176: ...ive sprocket M10 32 Nm 23 6 lbf ft Loctite 243 Screw cylinder head M10 1st stage 30 Nm 22 1 lbf ft 2nd stage 60 Nm 44 3 lbf ft Thread is oiled head flat is greased Water temperature sensor M10 14 Nm 10 3 lbf ft Screw plug cam lever axis M10x1 9 Nm 6 6 lbf ft Spark plug M12 15 Nm 11 1 lbf ft Nut inner clutch hub M16LHx1 5 120 Nm 88 5 lbf ft Loctite 243 Nut primary gear timing chain sprocket M16x1 5...

Page 177: ...rox 10 l 2 6 US gal Super unleaded ROZ 95 RON 95 PON 91 p 185 Fuel reserve approx 1 5 l 1 6 qt 23 4 Chassis Frame Lattice frame of steel tubes powder coated Fork WP Suspension Shock absorber WP Suspension Brake system Front Disc brake with four pot brake caliper Rear Disc brake with single piston brake caliper floating Suspension travel Front 125 mm 4 92 in Rear 150 mm 5 91 in Brake discs diameter...

Page 178: ...l payload Front 2 0 bar 29 psi Rear 2 2 bar 32 psi Secondary ratio 15 45 Chain 5 8 x 1 4 520 O ring Steering head angle 66 5 Wheelbase 1 340 15 mm 52 76 0 59 in Seat height unloaded 820 mm 32 28 in Ground clearance unloaded 178 mm 7 01 in Weight without fuel approx 152 5 kg 336 2 lb Maximum permissible front axle load 125 kg 276 lb Maximum permissible rear axle load 210 kg 463 lb Maximum permissib...

Page 179: ...0 30 A Low beam H11 Sockel PGJ19 2 12 V 55 W High beam H11 Sockel PGJ19 2 12 V 55 W Parking light LED Instrument lights and indicator lamps LED Turn signal LED Brake tail light LED License plate lamp LED 23 6 Tires Front tires Rear tires 110 70 ZR 17 M C 54W TL Metzeler SPORTEC M5 Interact 150 60 ZR 17 M C 66W TL Metzeler SPORTEC M5 Interact Additional information is available in the Service secti...

Page 180: ...er 90804010000 Shock absorber WP Suspension Spring preload Comfort 3 clicks Standard 5 clicks Sport 7 clicks Full payload 8 clicks Static sag 15 mm 0 59 in Riding sag 45 50 mm 1 77 1 97 in Fitted length 304 mm 11 97 in 23 9 Chassis tightening torques Exhaust clamp 10 Nm 7 4 lbf ft Screw chain guard EJOT PT K60x30 4 Nm 3 lbf ft Remaining nuts chassis M4 3 Nm 2 2 lbf ft Remaining screws chassis M4 3...

Page 181: ...bf ft Loctite 204 Screw cover in front of battery compart ment M5 4 Nm 3 lbf ft Screw fuel pump M5 5 Nm 3 7 lbf ft Screw fuel tank cover M5 5 Nm 3 7 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 tail end lower part M5 4 Nm 3 lbf ft Cap bolt footrest M6 9 Nm 6 6 lbf ft Nut foot brake lever adjustment M6 10 Nm 7 4 lbf ft Nut ...

Page 182: ...M6 7 Nm 5 2 lbf ft Loctite 243 Screw cable holder side stand switch M6 9 Nm 6 6 lbf ft Loctite 243 Screw chain guard M6 7 Nm 5 2 lbf ft Screw chain sliding guard M6 7 Nm 5 2 lbf ft Screw compensating tank M6 9 Nm 6 6 lbf ft Screw engine sprocket cover on frame M6 7 Nm 5 2 lbf ft Screw foot brake cylinder M6 9 Nm 6 6 lbf ft Loctite 243 Screw footrest bracket M6 7 Nm 5 2 lbf ft Screw front fender on...

Page 183: ... license plate holder on license plate bracket M6 7 Nm 5 2 lbf ft Screw magnetic holder on side stand M6 4 Nm 3 lbf ft Loctite 243 Screw mirror holder M6 9 Nm 6 6 lbf ft Screw passenger seat M6 7 Nm 5 2 lbf ft Screw radiator air inlet on frame M6 6 Nm 4 4 lbf ft Screw radiator holder M6 6 Nm 4 4 lbf ft Screw rear ABS sensor wheel M6 6 Nm 4 4 lbf ft Loctite 204 Screw rear fender M6 7 Nm 5 2 lbf ft ...

Page 184: ...43 Screw front wheel spindle M8 20 Nm 14 8 lbf ft Screw fuel tank attachment rear on frame M8 16 Nm 11 8 lbf ft Screw horn M8 7 Nm 5 2 lbf ft Screw main silencer M8 23 Nm 17 lbf ft Screw passenger footrest bracket M8 20 Nm 14 8 lbf ft Loctite 243 Screw rear brake disc M8 30 Nm 22 1 lbf ft Loctite 243 Screw shift lever M8 17 Nm 12 5 lbf ft Loctite 243 Screw top triple clamp M8 15 Nm 11 1 lbf ft Scr...

Page 185: ... 9 lbf ft Screw side stand bracket M10x1 25 33 Nm 24 3 lbf ft Loctite 243 Stud rear sprocket M10x1 25 50 Nm 36 9 lbf ft Nut rear wheel spindle M14x1 5 90 Nm 66 4 lbf ft Screw top steering head M16x1 5 52 Nm 38 4 lbf ft Loctite 204 Lambda sensor M18x1 5 15 Nm 11 1 lbf ft ...

Page 186: ...RAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Only use high quality coolant with corrosion inhibitor for aluminum motors even in countries with high temperatures Using inferior antifreeze can result in corrosion and foaming Mixture ratio Antifreeze protection 25 45 C 13 49 F anti corrosion antifreeze distilled water Recommended supplier Motorex COOLANT M3 0 Engine oil SAE 15...

Page 187: ... 4 Guideline Use only oils that comply with the specified standards see specifications on the container and that 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...

Page 188: ... 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 189: ...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 190: ...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 191: ...rear brake adding 108 Brake fluid level front brake checking 104 rear brake checking 107 Brake linings front brake checking 106 rear brake checking 109 Brakes 66 Brakes applying 66 C Capacity coolant 175 engine oil 175 fuel 71 175 Chain chain dirt accumulation checking 84 checking 89 cleaning 84 Chain tension adjusting 87 checking 85 Chassis number 20 Clutch cable play adjusting 150 Clutch lever 2...

Page 192: ...verage speed menu 46 service range menu 49 total distance menu ODO 51 warning notes 36 Coolant draining 144 Coolant level checking 141 compensating tank checking 139 compensating tank correcting 143 Cooling system 138 filling bleeding 145 Customer service 14 E Electric starter button 26 Emergency OFF switch 25 Engine running in 57 Engine number 21 Engine oil adding 154 changing 151 Engine oil leve...

Page 193: ...ing 137 High beam bulb changing 133 High beam flasher button 24 High beam headlight adjustment checking 136 Horn button 23 I Ignition lock 26 Indicator lamps 40 K Key number 21 Kilometers or miles adjusting 53 L Light switch 24 Loading the vehicle 58 Low beam bulb changing 132 Low beam headlight adjustment checking 135 M Motorcycle cleaning 156 raising with the front wheel stand 79 raising with th...

Page 194: ...or use 60 Protective clothing 11 R Rear hub rubber dampers checking 118 Rear sprocket checking 89 Rear wheel installing 117 removing 116 Riding 63 starting off 63 Right side cover installing 101 removing 100 S Safe operation 10 Seat lock 29 Service 13 Service schedule 72 74 Shift lever 31 adjusting 76 Shift speed RPM 1 adjusting 54 Shift speed RPM 2 adjusting 55 Shifting 63 Shock absorber spring p...

Page 195: ...1 engine tightening torques 172 fork 178 shock absorber 178 tires 177 Throttle grip 23 Time adjusting 53 Tire air pressure checking 121 Tire condition checking 120 Tool set 30 Transport 69 Troubleshooting 162 164 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 158 Work rules 11 ...

Page 196: ... 3213249en 3213249en 10 2014 KTM Motorrad AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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