KTM 390 Duke 2015 COL Page 100 Owner'S Manual Download

Page: 100 / 182

BRAKE SYSTEM

101897-10

–

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. 98)

–

Reconnect spring

12.7

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 390 Duke 2015 COL

Page 1: ...OWNER S MANUAL 2015 390 Duke 2015 COL Art no 3213123en ...

Page 2: ......

Page 3: ...y 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 opti...

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: ...el 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 Combination instrument 27 6 11 1 Overview 27 6 11 2 Activation and test 28 6 11 3 Wa...

Page 6: ...2 8 4 Shifting riding 62 8 5 Applying the brakes 65 8 6 Stopping parking 67 8 7 Transport 68 8 8 Refueling 69 9 SERVICE SCHEDULE 71 9 1 Service schedule 71 10 TUNING THE CHASSIS 73 10 1 Adjusting the spring preload of the shock absorber x 73 10 2 Adjusting the shift lever 74 11 SERVICE WORK ON THE CHASSIS 75 11 1 Raising the motorcycle with the rear wheel stand 75 11 2 Taking the motorcycle off of...

Page 7: ...e ABS fuses 118 14 5 Changing the fuses of individual power consumers 119 14 6 Changing the headlight bulb 121 14 7 Changing the parking light bulb 124 14 8 Checking the headlight setting 128 14 9 Adjusting the headlight range 129 15 COOLING SYSTEM 132 15 1 Cooling system 132 15 2 Checking the antifreeze and coolant level 133 15 3 Checking the coolant level 135 15 4 Draining the coolant x 137 15 5...

Page 8: ...ine oil 161 21 3 2 Coolant 161 21 3 3 Fuel 161 21 4 Chassis 161 21 5 Electrical system 163 21 6 Tires 163 21 7 Fork 164 21 8 Shock absorber 164 21 9 Chassis tightening torques 164 22 SUBSTANCES 169 23 AUXILIARY SUBSTANCES 172 24 STANDARDS 174 INDEX 175 ...

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 101923 10 ...

Page 19: ...4 VIEW OF VEHICLE 17 1 Combination instrument 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 21 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 101924 10 ...

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

Page 22: ...RIAL NUMBERS 20 5 1 Chassis number 101877 10 The chassis number 1 is stamped on the right of the steering head 5 2 Type label 101877 11 The type label 1 is on the right of the frame behind the steering head ...

Page 23: ... The engine number 1 is stamped on the left side of the engine under the engine sprocket 5 4 Key number B00755 10 The key number 1 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: ...ver 101878 10 The clutch lever 1 is fitted on the left side of the handlebar 6 2 Hand brake lever 101879 10 The hand brake lever 1 is fitted on the right side of the handlebar The front brake is engaged using the hand brake lever ...

Page 25: ...ottle grip 1 is fitted on the right side of the handlebar 6 4 Horn button B00706 11 The horn button 1 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 B00705 10 The high beam flasher button 1 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 actuat...

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 1 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 an...

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 igniti...

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: ...lay modes are total distance traveled TRIP 1 distance 1 ODO and distance 2 TRIP 2 Pressing and holding the SET button 2 resets the distance 1 TRIP 1 and distance 2 TRIP 2 functions to 0 0 and briefly pressing the SET button 2 changes the info display to the next display mode The ABS can be switched off using button 3 ...

Page 35: ...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 detect...

Page 36: ...ute The gear display 3 shows the engaged gear The coolant temperature appears in segment 4 The time appears in segment 5 The filling level in the fuel tank is displaced in segment 6 The info display 7 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 1 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 consumption 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 1 of the filler cap and insert the ignition key in the lock Note Danger of damage Ignition key brea...

Page 52: ... 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 101881 10 The seat lock 1 is located to the left of the seat It can be locked with the ignition key ...

Page 53: ...758 10 The tool set 1 is located under the passenger seat 6 16 Grab handles 101882 10 The grab handles 1 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: ...r 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 101885 11 Shift lever 1 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 101883 10 Foot brake lever 1 is located in front of the right footrest The foot brake lever is used to activate the rear brake ...

Page 56: ...he 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 99 Check the front brake linings p 96 Check the rear brake linings p 102 Check the brake system function Check the coolant level p 135 Check for chain dirt accumulation p 81 Check the chain tension p 82 Check the tire condition p 110 Check the tire air pressure p 111 Check the settings of all controls and ensure that they can be operated smoothly Check the functioning of the elect...

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: ... 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 64: ...aneously 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 8 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 W...

Page 65: ...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 66: ...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 101885 10 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 67: ...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 68: ...en 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 ...

Page 69: ...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 70: ...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 71: ...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 72: ... 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 1 of the fuel filler Total fuel tank capacity approx 11 l 2 9 US gal Super unleaded ROZ 95 RON 95 PON 91 p 170 Close the filler cap p 50 ...

Page 73: ... the brake discs p 93 Check the brake lines for damage and leakage Check the rear brake fluid level p 99 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 110 Check the tire air pressure p 111 Check the chain rear sprocket and engine sprocket p 86 Check the chain tension p 82 Grease all moving parts e g side stand...

Page 74: ... 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 128 Check that the radiator fan is functioning properly x Final check Check the vehicle for roadworthiness and take a test ride Rea...

Page 75: ...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 101886 10 Adjust the spring preload by turning adjusting ring 1 Guideline Spring preload Standard 3 clicks Full ...

Page 76: ...e same adjustments on both sides At least five screw threads must be screwed into the seating Check adjusting angle B Guideline Adjusting angle B shift rod linkage shift lever 75 Tighten nuts 1 Info After the nuts have been tightened the bearings of the shift rod must be central and aligned identically to each other in order to ensure freedom of movement in the bearing shells Check the shift lever...

Page 77: ...01 Mount the support of the wheel stand Insert the adapter in the rear wheel stand Adapter 61029055130 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 place the vehicle on a firm...

Page 78: ...e on the side stand 1 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 75 101887 10 Condition Remove cap 1 ...

Page 79: ...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 101889 01 Secure the motorcycle against falling over Remove the front wheel stand ...

Page 80: ...887 10 Mount cap 1 11 5 Removing the passenger seat 101881 10 Insert the ignition key in seat lock 1 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 81: ...o 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 78 101891 10 Main work Remove screws 1 Raise the rear of the seat pull ...

Page 82: ... CHASSIS 80 11 8 Mounting the seat 101892 10 Main work Attach seat recesses A at screws 1 and lower at the rear Mount and tighten screws 2 Guideline Screw seat M6 11 Nm 8 1 lbf ft Finishing work Mount the passenger seat p 79 ...

Page 83: ...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 84: ...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 85: ... guard press the chain upward toward the swingarm and determine chain tension A Info The upper chain section B 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 84 ...

Page 86: ... 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 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 necess...

Page 87: ...that the markings on the left and right chain adjuster 4 are in the same position in relation to reference marks C 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 2 Make sure that chain adjusters 4 are fitted correctly on adjusting screws 3 Tighten nut 1 Guidel...

Page 88: ...ain 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 x Info The engine sprocket rear sprocket and chain should always be replaced together ...

Page 89: ... 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 B at the longest chain section 301 6 mm 11 874 in If the distance B 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 wea...

Page 90: ...the chain guard aside C00199 10 Check the chain sliding guard for wear If drill hole D becomes visible on the chain sliding guard in area C 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 91: ...1416 10 Position the chain guard and tighten screw 1 Guideline Screw chain guard EJOT PT 4 Nm 3 lbf ft Tighten screw 2 Guideline Screw chain guard EJOT PT 4 Nm 3 lbf ft Tighten screw 3 Guideline Remaining screws chassis M5 5 Nm 3 7 lbf ft ...

Page 92: ...11 SERVICE WORK ON THE CHASSIS 90 11 14 Removing the front spoiler 101895 10 Remove screws 1 101896 10 Remove screws 2 Take off the front spoiler ...

Page 93: ...ront spoiler 101895 10 Position the front spoiler Mount screws 1 but do not tighten yet 101896 10 Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Tighten screw 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 94: ...mmended 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 luggag...

Page 95: ...auses 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 4 can be used to switch ABS off manually see Starting 12 2 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc s Change the worn...

Page 96: ...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 C00200 10 Move the brake ...

Page 97: ...protective clothing and goggles 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 Hazar...

Page 98: ... spilt brake fluid immediately with water 12 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 linin...

Page 99: ...ke linings for damage and cracking If there is wear or tearing Change the front brake linings x 12 6 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 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 specifica...

Page 100: ...2 in If the free travel does not meet specifications Adjust the free travel of the foot brake lever x p 98 Reconnect spring 1 12 7 Adjusting the free travel of the foot brake lever x 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 fo...

Page 101: ...ge of adjustment is limited Hold screw 3 and tighten nut 2 Attach spring 1 12 8 Checking the rear brake fluid level Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help ...

Page 102: ...ing rear 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 contact with skin and...

Page 103: ...vironmental damage Oil grease filters fuel cleaners brake 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 101899 10 Stand the vehicle upright Remove screw cap 1 with membrane 2 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 169 Refit ...

Page 104: ...d 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 B01390 10 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings x Check th...

Page 105: ...out of the hole Loosen screws 4 and screw 5 Unscrew screw 5 about six turns and press your hand on the screw to push the wheel spindle out of the axle clamp Remove screw 5 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 whe...

Page 106: ... Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary B01392 10 Main work 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 1 and mating surfaces A of the spacers Long life grease p 172 Insert the spacers ...

Page 107: ...ideline Screw wheel speed sensor holder M6 8 Nm 5 9 lbf ft Mount and tighten screws 5 Take the motorcycle off of the front wheel stand p 77 Pull the front brake and push down hard on the fork several times to align the fork legs Tighten screws 6 Guideline Screw fork stub M8 15 Nm 11 1 lbf ft Finishing work Take the motorcycle off of the rear wheel stand p 75 13 3 Removing the rear wheel x Preparat...

Page 108: ... 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 operate the foot brake when the rear wheel is removed 13 4 Installing the rear wheel x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the b...

Page 109: ...the wheel bearing is damaged or worn Change the wheel bearing x Clean and grease the shaft seal rings 1 and mating surfaces A of the spacers Long life grease p 172 Clean the thread of the wheel spindle and nut 2 Clean the fixing locations on the brake caliper support and swingarm Install the rubber damper and rear sprocket carrier on the rear wheel Position the rear wheel The brake linings are cor...

Page 110: ...djusters must be in the same position relative to the reference marks B Nut rear wheel spindle M14x1 5 90 Nm 66 4 lbf ft Insert wheel speed sensor 5 into the hole Mount and tighten screw 6 Guideline Screw wheel speed sensor holder M6 8 Nm 5 9 lbf ft Finishing work Take the motorcycle off of the rear wheel stand p 75 13 5 Checking the rear hub rubber dampers x Info The engine power is transmitted f...

Page 111: ...hange all rubber dampers in the rear hub 101926 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 A 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 A is larger than the specified value Change...

Page 112: ...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 113: ...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 114: ...13 WHEELS TIRES 112 If the tire air pressure does not meet specifications Correct the tire air pressure Mount the dust cap ...

Page 115: ...ery 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 78 Remove the seat p 79 101903 10 Main work Pull back the negative terminal cove...

Page 116: ... 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 101904 11 Main work Position the battery in the battery holder Info The battery terminals must be at the top Attach rubber band 1 Reconnect the positive cable 2 of the battery Position positive ...

Page 117: ...jury 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 w...

Page 118: ...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 119: ...nator With this device you cannot overcharge the battery Info Never remove lid 1 Charge the battery with a maximum of 10 of the capacity specified on battery housing 2 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 Mou...

Page 120: ...rd fuse which protects the ABS control unit is located in the fuse box Preparatory work Switch off all power consumers and the engine Remove the passenger seat p 78 101905 10 To change the fuse of the ABS hydraulic unit Take off the protection cap and remove fuse 1 Info A defective fuse is indicated by a burned out fuse wire A Warning Fire hazard The electrical system can be overloaded if the wron...

Page 121: ... if the wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Use spare fuses with the correct rating only Fuse 90111088025 Tip Replace spare fuse C in the fuse box so that it is available if needed Mount the protection cap Finishing work Mount the passenger seat p 79 14 5 Changing the fuses of individual power consumers Info The fuse box with the main fuse...

Page 122: ...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 ABS control unit Fuse 8 10 A combination instrument control unit Fuse 9 10 A auxiliary equipment Info A defective fuse is indicated by a burned out fuse wire A Warning Fire hazard The electrical system can be overloaded if the wrong fuses...

Page 123: ...onsumer is functioning properly Close the fuse box cover Finishing work Mount the passenger seat p 79 14 6 Changing the headlight bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off all power consumers and switch off the engine ...

Page 124: ...CTRICAL SYSTEM 122 101907 10 Main work Remove expanding rivets 1 101908 10 Remove screws 2 Lift the headlight mask slightly and swing forward B00760 10 Take off protection cap 3 Disconnect plug in connector 4 ...

Page 125: ...headlight housing Headlight H4 socket P43t p 163 Info Insert the headlight bulb so that the catches latch into the recesses Attach retaining clamp 5 B00760 10 Connect plug in connection 4 Mount protection cap 3 101908 10 Fold the headlight mask up Mount and tighten screws 2 Guideline Screw headlight mask M6 11 Nm 8 1 lbf ft ...

Page 126: ...ging 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 Preparatory work Switch off all power consumers and switch off the engine 101907 10 Main work Remove expanding rivets 1 ...

Page 127: ...14 ELECTRICAL SYSTEM 125 308243 10 Remove screws 2 Lift the headlight mask slightly and swing forward B00762 10 Remove screws 3 Take off cover 4 ...

Page 128: ... the socket with bulb 5 out of the housing Remove the bulb Position a new light bulb in the socket Parking light W5W socket W2 1x9 5d p 163 Position the socket with bulb 5 in the housing B00762 10 Position cover 4 Mount and tighten screws 3 ...

Page 129: ...TEM 127 308243 10 Fold the headlight mask up Mount and tighten screws 2 Guideline Screw headlight mask M6 11 Nm 8 1 lbf ft 101907 10 Mount expanding rivets 1 on both sides Check that the lighting is functioning properly ...

Page 130: ...cm 2 in Position the vehicle vertically at a distance A in front of the wall and switch on the low beam Guideline Distance A 5 m 16 ft The rider with luggage and passenger if applicable now mounts the motorcycle Check the headlight setting The light 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...

Page 131: ...14 ELECTRICAL SYSTEM 129 14 9 Adjusting the headlight range 101907 10 Main work Remove expanding rivets 1 101908 10 Remove screws 2 Lift the headlight mask slightly and swing forward ...

Page 132: ...licable 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 101908 10 Fold the headlight mask up Mount and tighten screws 2 Guideline Screw headlight mask M6 11 Nm 8 1 lbf ft 101907 10 Mount expanding rivets 1 on both sides ...

Page 133: ...14 ELECTRICAL SYSTEM 131 Finishing work Check the headlight setting p 128 ...

Page 134: ...he cooling system is regulated by a valve in radiator cap 2 Heat expansion causes excess coolant to flow into compensating tank 3 When the temperature falls this surplus coolant is sucked 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 135: ...fins 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 136: ...ed with coolant Keep coolant out of reach of children Condition The engine is cold 101910 10 Stand the motorcycle upright on a horizontal surface Remove the cap of the compensating tank 1 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 betwee...

Page 137: ...of the loss Alternative 1 Coolant p 169 Alternative 2 Coolant mixed ready to use p 169 If you had to add more coolant than the specified amount 0 20 l 0 21 qt Fill bleed the cooling system x p 138 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 138: ...oolant out of reach of children Condition The engine is cold 101910 10 Stand the motorcycle upright on a horizontal surface Check the coolant level in the compensating tank 1 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 169 Alternative 2 Coolant mixed ready to use p 169 101911 10 Remove radiator ca...

Page 139: ...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 140: ...ing 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 141: ...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 101910 11 Stop the engine and allow it to cool down When the engine is cool check the coo...

Page 142: ...meet specifications Adjust the play in the throttle cable x p 141 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 ...

Page 143: ...lay 101914 10 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 A 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 142 Note Clutch damage If there is no play on the clutch lever the clutch will begin to slip When o...

Page 144: ...able 16 4 Adjusting the clutch cable play x 101915 10 Move the handlebar to the straight ahead position Push back sleeve 1 Loosen lock nut 2 Adjust the play in the clutch level A by turning adjusting screw 3 Guideline Clutch lever play 1 3 mm 0 04 0 12 in Tighten lock nut 2 Slide on sleeve 1 ...

Page 145: ...ge of the oil level viewer If the engine oil level is not at the specified level Add the engine oil p 146 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 146: ...ine Remove the oil drain plug 1 with the O ring Remove oil screen 2 with the O ring Remove screw plug 3 with oil screen 4 Completely drain the engine oil Thoroughly clean the oil drain plugs and oil screens Position oil screen 2 and mount and tighten oil drain plug 1 with the O ring Guideline Oil drain plug M24x1 5 15 Nm 11 1 lbf ft Mount and tighten screw plug 3 with oil screen 4 and the O ring G...

Page 147: ...rs reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing area 101919 10 Insert oil filter 7 Oil the O ring of the oil filter cover Mount oil filter cover 6 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 148: ...s 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 check that it is oil tight Finishing work Fit the front spoiler p 91 Check the engine oil level p 143 17 3 Adding engine oil Info ...

Page 149: ...propriate 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 che...

Page 150: ... 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 151: ...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 152: ...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 148 Clean the brakes Info After EVERY trip on salted roads thoroughly wash...

Page 153: ...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 81 ...

Page 154: ... 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 172 Refuel p 69 Clean the motorcycle p 148 Change the engine oil and oil filter clean the oil screen x p 143 Check the antifreeze and coolant level p 133 Check the tire air pressure p 111 Remove the battery x p 113 Recharge the battery x p 115 Guideline Storage temperature of b...

Page 155: ... 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 77 Take the motorcycle off of the rear wheel stand p 75 Recharge the battery x p 115 Install the battery x p 114 Se...

Page 156: ...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 157: ...t again Malfunction in ABS Read out the ABS fault memory using the KTM diagnostics tool x 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 143 Engine oil too thin low viscosity Change the engine oil and oil filter clean the oil screen x p 143 Headlight and parking light are not functioning ...

Page 158: ...Check the open circuit current x Combination instrument shows nothing on the display Fuse 8 blown Change the fuses of individual power consumers p 119 Set the clock p 46 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 159: ... 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 160: ... 04 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 550 1 650 rpm Starting aid Electric starter 21 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 161: ...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 162: ...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 timing chain sprocket M14 55 Nm 40 6 lbf ft Loctite 243 Nut inner clutch hub M16LHx1 5 120 Nm 88 5 lbf f...

Page 163: ... 169 Coolant mixed ready to use p 169 21 3 3 Fuel Total fuel tank capacity approx 11 l 2 9 US gal Super unleaded ROZ 95 RON 95 PON 91 p 170 Fuel reserve approx 1 5 l 1 6 qt 21 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 S...

Page 164: ...ire air pressure with passenger full 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 65 Wheelbase 1 367 15 mm 53 82 0 59 in Seat height unloaded 800 mm 31 5 in Ground clearance unloaded 172 mm 6 77 in Weight without fuel approx 142 kg 313 lb Maximum permissible front axle load 125 kg 276 lb Maximum permissible rear axle load 210...

Page 165: ...88030 30 A Headlight H4 socket P43t 12 V 60 55 W Parking light W5W socket W2 1x9 5d 12 V 5 W Instrument lights and indicator lamps LED Turn signal LED Brake tail light LED License plate lamp LED 21 6 Tires Front tires Rear tires 110 70 ZR 17 M C 54W TL Metzeler SPORTEC MS 150 60 ZR 17 M C 66W TL Metzeler SPORTEC MS Additional information is available in the Service section under http www ktm com ...

Page 166: ...r WP Suspension Spring preload Standard 3 clicks Full payload 10 clicks Static sag 15 mm 0 59 in Riding sag 50 55 mm 1 97 2 17 in Fitted length 300 mm 11 81 in 21 9 Chassis tightening torques Screw chain guard EJOT PT 4 Nm 3 lbf ft Screw headlight EJOT PT 4 Nm 3 lbf ft Remaining screws chassis M4 4 Nm 3 lbf ft Screw EFI control unit M4 4 Nm 3 lbf ft Screw trim subframe bottom M4 2 Nm 1 5 lbf ft Re...

Page 167: ...3 Screw spoiler M5 5 Nm 3 7 lbf ft Screw subframe cover bottom M5 5 Nm 3 7 lbf ft Loctite 243 Screw windshield M5 3 Nm 2 2 lbf ft Nut foot brake lever adjustment M6 10 Nm 7 4 lbf ft Nut radiator M6 5 Nm 3 7 lbf ft Remaining nuts chassis M6 15 Nm 11 1 lbf ft Remaining screws chassis M6 10 Nm 7 4 lbf ft Screw air filter box M6 6 Nm 4 4 lbf ft Screw bottom of rear part M6 11 Nm 8 1 lbf ft Screw brake...

Page 168: ...or holder M6 11 Nm 8 1 lbf ft Screw seat M6 11 Nm 8 1 lbf ft Screw shift activation M6 11 Nm 8 1 lbf ft Loctite 243 Screw voltage regulator M6 10 Nm 7 4 lbf ft Screw voltage regulator holder M6 15 Nm 11 1 lbf ft Screw wheel speed sensor holder M6 8 Nm 5 9 lbf ft Nut rear sprocket screw M8 27 Nm 19 9 lbf ft Remaining nuts chassis M8 30 Nm 22 1 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft Sc...

Page 169: ...ting 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 ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Banjo bolt brake line M10x1 20 Nm 14 8 lbf ft Fitting handlebar support M10x1 25 21 Nm 15 5 lbf ft Nut turn signal M10x1 25 6 Nm 4 4 lbf ft Screw front footrest bracket M10x1 25 46 Nm 33 9 lbf ft Screw side stand bracket M10x1 25 25 Nm 18 4...

Page 170: ...NICAL DATA 168 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 171: ...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 172: ...ded supplier Motorex Formula 4T Fork oil SAE 4 48601166S1 Standard classification SAE p 174 SAE 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 equi...

Page 173: ...22 SUBSTANCES 171 Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 ...

Page 174: ... 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 175: ...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 176: ...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 177: ...ing 96 rear brake checking 102 Brakes 65 Brakes applying 65 C Capacity coolant 161 engine oil 161 fuel 70 161 Chain chain dirt accumulation checking 81 checking 86 cleaning 81 Chain tension adjusting 84 checking 82 Chassis number 20 Clutch cable play adjusting 142 Clutch lever 22 Clutch lever play checking 141 Combination instrument activation and test 28 average fuel consumption 1 average fuel co...

Page 178: ...3 135 Cooling system 132 filling bleeding 138 Customer service 14 E Electric starter button 26 Emergency OFF switch 25 Engine running in 56 Engine number 21 Engine oil adding 146 changing 143 Engine oil level checking 143 Engine sprocket checking 86 Environment 11 F Figures 14 Filler cap closing 50 opening 48 Filling up fuel 69 Foot brake lever 53 free travel adjusting 98 free travel checking 97 F...

Page 179: ...sing with the front wheel stand 76 raising with the rear wheel stand 75 taking off of the front wheel stand 77 taking off of the rear wheel stand 75 O Oil filter changing 143 Oil screen cleaning 143 Operating substances 13 Owner s Manual 12 P Parking 67 Parking light bulb changing 124 Passenger footrests 52 Passenger seat mounting 79 removing 78 Play in throttle cable adjusting 141 checking 140 Pr...

Page 180: ...peed RPM 1 adjusting 47 Shift speed RPM 2 adjusting 47 Shifting 62 Shock absorber spring preload adjusting 73 Side stand 54 Spare parts 13 Starting 60 Steering lock 26 Stopping 67 Storage 152 T Technical data capacities 161 chassis 161 chassis tightening torques 164 electrical system 163 engine 157 engine tightening torques 158 fork 164 shock absorber 164 tires 163 Throttle grip 23 Time adjusting ...

Page 181: ...ansport 68 Troubleshooting 154 156 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 150 Work rules 11 ...

Page 182: ... 3213123en 3213123en 11 2013 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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KTM 390 Duke 2015 COL, Owner'S Manual

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