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KTM 690 Duke AUS 2012, Owner'S Manual

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KTM 690 Duke AUS 2012 Owner'S Manual Download Page 7

TABLE OF CONTENTS

5

Filling/bleeding the cooling system

x

.............................. 114

TUNING THE ENGINE ........................................................ 116

Setting the engine characteristics .................................... 116
Checking the basic position of the shift lever..................... 117
Adjusting the basic position of the shift lever

x

............... 117

SERVICE WORK ON THE ENGINE ....................................... 119

Changing the engine oil and filter, cleaning the oil
screens

x

..................................................................... 119

Checking the engine oil level ........................................... 123
Adding engine oil ........................................................... 124

CLEANING, CARE .............................................................. 125

Cleaning motorcycle ....................................................... 125
Checks and maintenance steps for winter operation ........... 127

STORAGE .......................................................................... 128

Storage.......................................................................... 128
Preparing for use after storage ......................................... 129

TROUBLESHOOTING.......................................................... 130
BLINK CODE ..................................................................... 133
TECHNICAL DATA - ENGINE............................................... 140

Capacity - engine oil ....................................................... 141
Capacity - coolant........................................................... 141

TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 142
TECHNICAL DATA - CHASSIS ............................................. 146

Lighting equipment ........................................................ 147
Tires ............................................................................. 148
Capacity - fuel................................................................ 148

TECHNICAL DATA - FORK................................................... 149
TECHNICAL DATA - SHOCK ABSORBER .............................. 150
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 151

SUBSTANCES.................................................................... 155
AUXILIARY SUBSTANCES................................................... 159
STANDARDS...................................................................... 161
INDEX ............................................................................... 162

Summary of Contents for 690 Duke AUS 2012

Page 1: ...OWNER S MANUAL 2012 690 Duke EU 690 Duke AUS UK Art no 3211788en ...

Page 2: ......

Page 3: ...e time of going to print Minor differences due to developments in design cannot be ruled out completely 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...

Page 4: ...ds is permitted only with the express written permission of the copyright owner ISO 9001 12 100 6061 According to the international quality management standard ISO 9001 KTM uses quality assurance processes that lead to the maximum possible quality of the products Issued by TÜV Management Service KTM Sportmotorcycle AG 5230 Mattighofen Austria ...

Page 5: ...nt indicator lamps 25 Combination instrument display 26 Combination instrument speedometer 27 Setting kilometers or miles 27 Combination instrument time 28 Setting the clock 29 Combination instrument display ODO 29 Combination instrument setting resetting TRIP 1 30 Combination instrument setting resetting TRIP 2 30 Combination instrument TRIP F display 31 Combination instrument GEAr display 32 Com...

Page 6: ...luid x 72 Checking the front brake linings 74 Checking the free travel of foot brake lever 74 Adjusting the basic position of the foot brake lever x 75 Checking rear brake fluid level 76 Adding rear brake fluid x 77 Checking the rear brake linings 78 WHEELS TIRES 80 Removing the front wheel x 80 Installing the front wheel x 81 Removing the rear wheel x 83 Installing the rear wheel x 84 Checking th...

Page 7: ...engine oil 124 CLEANING CARE 125 Cleaning motorcycle 125 Checks and maintenance steps for winter operation 127 STORAGE 128 Storage 128 Preparing for use after storage 129 TROUBLESHOOTING 130 BLINK CODE 133 TECHNICAL DATA ENGINE 140 Capacity engine oil 141 Capacity coolant 141 TECHNICAL DATA ENGINE TIGHTENING TORQUES 142 TECHNICAL DATA CHASSIS 146 Lighting equipment 147 Tires 148 Capacity fuel 148 ...

Page 8: ...standing In the interest of your own safety have these jobs performed by an authorized KTM workshop There your motorcycle will be serviced opti mally by specially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page Formats used The typographical formats used in this document are explained below Specific name Identifies a...

Page 9: ...dirty or wet roads can lead to above average wear of components such as the transmission train or the brakes For this reason it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached It is imperative that you adhere to the stipulated run in times and service intervals If you observe these exactly you will ensure a much longer service life fo...

Page 10: ...arenthe ses Ex Hook wrench T106S During assembly non reusable parts e g self locking screws and nuts seals and seal rings O rings pins lock washers must be replaced by new parts Where thread lockers are used on screw connections e g Loctite follow the instructions for use from the manufacturer After disassembly clean the parts that are to be reused and check them for damage and wear Change damaged...

Page 11: ...d to conflicts with other persons But if you use your motorcycle responsibly you can ensure that such problems and conflicts do not have to occur To protect the future of motorcycle sport make sure that you use your motorcycle legally display environmental consciousness and respect the rights of others Notes warnings Pay close attention to the notes warnings Info Various information and warning la...

Page 12: ...ntifies a danger that will lead to environmental damage if the appropriate measures are not taken Owner s manual It is important that you read this owner s manual carefully and completely before making your first trip It contains useful information and tips to help you operate and handle your motorcycle Only then will you find out how to customize the motorcycle ideally for your own use and how yo...

Page 13: ...11 ...

Page 14: ...VIEW OF VEHICLE 12 3 1 View of vehicle front left side example B00914 10 ...

Page 15: ...VIEW OF VEHICLE 13 1 Combination instrument p 24 2 Rear mirror 3 Clutch lever p 19 4 Seat 5 Passenger seat 6 Handrails p 35 7 Seat lock p 34 8 Engine number p 16 9 Shift lever p 36 10 Side stand p 38 ...

Page 16: ...VIEW OF VEHICLE 14 3 2 View of vehicle rear right side example B00915 10 ...

Page 17: ...ch p 21 2 Turn signal switch p 21 2 Horn button p 22 3 Filler cap 4 Ignition steering lock p 23 5 Emergency OFF switch p 22 5 Electric starter button p 23 6 Hand brake lever p 19 7 Chassis number type label p 16 8 Fuse box 9 Passenger footrests p 36 10 Foot brake lever p 37 11 Level viewer engine oil ...

Page 18: ... 10 The chassis number 1 is stamped on the right of the steering head The type label 2 is on the right of the frame behind the steering head 4 2 Engine number B00917 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket ...

Page 19: ...5 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 4 4 Fork part number B00918 10 The fork part number 1 is stamped on the inner side of the fork stub ...

Page 20: ...SERIAL NUMBERS 18 4 5 Shock absorber part number B00921 10 The shock absorber part number 1 is shown on a sticker applied to the shock absorber case ...

Page 21: ...r 1 is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 5 2 Hand brake lever B00920 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 22: ...ht switch B00924 11 The light switch 1 is fitted on the left side of the handlebar Possible states Low beam on Light switch is turned downwards In this position the low beam and tail light are switched on High beam on Light switch is turned upwards In this position the high beam and the tail light are switched on ...

Page 23: ...l switch B00923 10 The turn signal switch 1 is fitted on the left side of the handlebar Possible states Turn signal off Left turn signal on The turn signal switch is pressed to the left The turn signal switch automatically returns to the central position after use Right turn signal on The turn signal switch is pressed to the right The turn signal switch automatically returns to the central positio...

Page 24: ...operated in this position 5 8 Emergency OFF switch B00998 11 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 inter rupted a running engine stops and the engine cannot be started Emergency OFF switch on This position is necessary for operation as the ignition circuit is closed ...

Page 25: ...ing lock B00925 01 The ignition steering lock 1 is located 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 ig...

Page 26: ... p 25 3 Indicator lamps p 25 4 Display p 26 5 12 Combination instrument function buttons 401426 10 You can change the display mode with the MODE button 1 Possible display modes are the odometer ODO trip master 1 TRIP 1 trip master 2 TRIP 2 and gear display GEAr Press the SET button 2 to reset the trip master 1 function TRIP 1 and trip master 2 func tion TRIP 2 to 0 0 The ABS can be switched off us...

Page 27: ...ating state of the motorcy cle Possible states The turn signal indicator lamp flashes green simultaneously with the turn signal The turn signal is switched on The idle 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 temperature warning lamp lights up red The coolant temperature has reached a criti...

Page 28: ...d an emission or safety critical error The battery warning lamp lights up red The voltage in the vehicle system is too low The ABS warning lamp lights up flashes red Status or error messages relating to ABS antilock brake system 5 15 Combination instrument display 400836 01 When you switch on the ignition all display segments light up for one second as a function test ...

Page 29: ...7 front wheel with a series pro duction tire The display then changes to the last selected mode 5 16 Combination instrument speedometer 401443 10 The speed 1 is shown in kilometers per hour km h or in miles per hour mph 5 17 Setting kilometers or miles Info If you change the unit the value ODO is retained and converted accordingly Making the setting according to the country ...

Page 30: ...on Press the MODE button repeatedly until the ODO mode is active Keep the MODE button pressed until the display mode changes from km h to mph or from mph to km h 5 18 Combination instrument time 401443 11 The time is shown in area 1 of the display Info After reconnecting the battery or changing the fuse the time must be reset ...

Page 31: ... SET button pressed simultaneously The time display begins to flash Press the MODE button to set the hour Press the SET button to set the minute Keep the MODE button and the SET button pressed simultaneously The time is set 5 20 Combination instrument display ODO 401444 01 In the ODO display mode the total distance traveled is shown in kilometers or miles Info This value is retained even if the ba...

Page 32: ...again 401445 01 Switch on the ignition by turning the ignition key to the position Press the MODE button repeatedly until the TRIP 1 mode is active Keep the SET button pressed The TRIP 1 display is set to 0 0 5 22 Combination instrument setting resetting TRIP 2 Info The TRIP 2 trip counter is always running and counts up to 999 9 The trip counter can be used to measure the distance covered during ...

Page 33: ...tive Keep the SET button pressed The TRIP 2 display is set to 0 0 5 23 Combination instrument TRIP F display 401447 01 If the fuel level drops to the reserve mark the display automatically changes to TRIP F and starts to count from 0 0 regardless of the previous display mode Info The low fuel warning lamp lights up in parallel to the TRIP F display ...

Page 34: ...mperature indicator 700124 01 The temperature display consists of 12 bars The more bars that light up the hotter the coolant When the upper bar lights up all bars in the display begin to flash and the temper ature warning lamp lights up Possible states Engine cold Up to four bars light up Engine warm Five to eleven bars light up Engine hot All twelve bars flash ...

Page 35: ...yes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc tor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister according to regulations and keep it out of the reach of children Warning Environmental hazard Improper handling of fuel is a danger to the environment...

Page 36: ... is highly flammable poisonous and harmful to your health When closing the filler cap ensure that it is closed correctly Change cloth ing that came into contact with fuel Immediately clean skin that came into contact with fuel using soap and water Remove the ignition key and close the cover 5 28 Seat lock B00928 10 The seat lock 1 is located on the left side of the vehicle It can be locked with th...

Page 37: ...B00929 10 The tool set 1 is located under the passenger seat 5 30 Handrails B00930 10 The handrails 1 are used for moving the motorcycle around When you have a passenger the passenger can hold on the handrails during the journey ...

Page 38: ...ootrests can be folded up and down Possible states Passenger footrests folded up For operation without a passenger Passenger footrests folded down For operation with a passenger 5 32 Shift lever B00932 11 The shift lever 1 is mounted on the left side of the engine ...

Page 39: ... can be seen in the photograph The neutral or idle position is between the first and second gears 5 33 Foot brake lever B00933 10 Foot brake lever 1 is located in front of the right footrest The rear brake is engaged with the foot brake lever ...

Page 40: ...folded up during motorcycle use The side stand is coupled with the safety electric starter system see the riding instructions Possible states Side stand folded out The vehicle can be supported on the side stand The safety electric starter system is active Side stand folded in This position is mandatory when riding the motorcycle The safety electric starter system is inactive ...

Page 41: ...shing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control 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 sp...

Page 42: ...t trip read the entire operating instructions carefully Get to know the controls Adjust the basic position of the clutch lever p 67 Adjust the basic position of the hand brake lever p 70 Adjust the basic position of the foot brake lever x p 75 Get used to handling the motorcycle on a suitable piece of land before making a longer trip Try also to ride as slowly as possible to get a better feel for ...

Page 43: ... handling characteristics at high speed Adapt your speed according to your payload Ride more slowly if your motorcycle is loaded with cases or other baggage Maximum speed with baggage 130 km h 80 8 mph 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 o...

Page 44: ... cannot be burned or singed by the hot exhaust system If you carry any baggage make sure it is fixed firmly as close as possible to the center 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 350 kg 772 lb Maximum permissible front axle load 150 kg...

Page 45: ...evel p 76 Check the front brake linings p 74 Check the rear brake linings p 78 Check the brake system function Check the coolant level in the compensating tank p 111 Check the chain for dirt p 60 Check the chain tension p 62 Check the tire condition p 88 Check the tire pressure p 90 Check the settings of all controls and ensure that they can be operated smoothly Check that the electrical equipment...

Page 46: ...ld engines have a negative effect on the service life of the engine Always warm up the engine at low engine speeds B00782 10 Turn the emergency OFF switch to the position Switch on the ignition by turning the ignition key to the position After you switch on the ignition you can hear the fuel pump working for about two seconds The function test of the combination instrument is run at the same time ...

Page 47: ...cycle is equipped with a safety start system You can only start the engine if the transmission is in neutral or if the clutch is pulled when a gear is engaged If the side stand is folded out and you shift into gear and release the clutch the engine stops Take the weight off the side stand and swing it back up with your foot as far as it will go 401426 11 Switching off ABS KTM recommends riding wit...

Page 48: ...can lock up Warning Danger of accidents Malfunctions caused by incorrect ignition key position Do not change the ignition key position during a journey Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle Make all adjustments when the vehicle is at a standstill Warning Risk of injury Falling off of the passenger The passenger must be capable of properly holdi...

Page 49: ...e tires have been run in Warning Danger of accidents Unstable handling characteristics Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational and with a full tank driver and passenger with protective clothing and helmet baggage Warning Danger of accidents Unstable handling characteristics due to slipped baggage Check the way your baggage is ...

Page 50: ...ear release the clutch and open the throttle Info You can see the positions of the six forward gears in the figure The neutral or idle position is between the first and second gears First gear is used for starting off or for steep inclines The operating temperature is reached when 5 bars of the temperature indicator light up After reaching maximum speed by fully opening the throttle turn the throt...

Page 51: ...ying the brakes Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes Clean or dry dirty or wet brakes 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 accidents Fa...

Page 52: ...arning 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 When braking release the throttle and apply the front and rear brakes at the same time Info When ABS is active you can achieve maximum braking power even on low grip surfaces such as sandy wet or slippery terrain...

Page 53: ...such as exhaust system radiator engine shock absorber and brakes Allow these components to cool down before starting 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 D...

Page 54: ...n To make the steering lock engage more easily move the handlebar a little to the left and right Remove the ignition key 7 7 Refueling 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 fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel...

Page 55: ...not allow fuel to get into the ground water the ground or the sewage system B00935 10 Switch off the engine Open the filler cap p 33 Fill the fuel tank with fuel up to the lower edge A of the filler neck Total fuel tank capacity approx 14 l 3 7 US gal Super unleaded ROZ 95 RON 95 PON 91 p 157 Close the filler cap p 34 401429 10 Press the SET button 2 for two seconds The low fuel warning lamp 1 swi...

Page 56: ... lines for damage and leakage Check the rear brake fluid level p 76 Check the free travel of the foot brake lever p 74 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 88 Check the tire pressure p 90 Check the chain rear sprocket and engine sprocket p 65 Check the chain tension p 62 Grease all moving parts e g si...

Page 57: ...x Check rectify the fluid level of the hydraulic clutch p 68 Check the screws and nuts for tightness x Change the front brake fluid x Change the rear brake fluid x Check the clutch x Check the headlight setting p 107 Check that the radiator fan is functioning properly x Final check Check the vehicle for roadworthiness and take a test ride Read out the fault memory using the KTM diagnostics tool af...

Page 58: ...Info The 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 B00936 10 Adjust the spring preload by turning adjustment unit 1 Guideline Spring preload Standard 4 cl...

Page 59: ...Main work Move the handlebar to the straight ahead position Attach the lifting gear to the steering stem Adapter 61029955620 Front wheel stand 61029055500 Info Always raise the rear of the motorcycle first Raise the front of the motorcycle 10 2 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 a...

Page 60: ... Mount the support of the wheel stand Insert the adapter in the rear wheel stand Adapter 61029055120 Rear wheel stand 61029055400 Stand the motorcycle upright align the wheel stand with the link fork and the adapters and lift the motorcycle 10 4 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 a...

Page 61: ...e the rear wheel stand and lean the vehicle on the side stand 10 5 Removing the passenger seat B00928 10 Insert the ignition key in seat lock 1 and turn it clockwise Raise the rear of the passenger seat push it towards the rear and remove it upward Remove the ignition key from the seat lock ...

Page 62: ... seat until it clicks into 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 10 7 Checking the chain for dirt 400678 01 Check the chain for heavy soiling If the chain is very dirty Clean the ...

Page 63: ...d grease and clean them with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info The service life of the chain depends largely on its maintenance 400725 01 Clean the chain regularly Rinse off loose dirt with a soft jet of water Re...

Page 64: ...nsmission can break On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check the chain tension and correct if necessary B01000 10 Lean the motorcycle on the side stand Shift gear to neutral Push the chain upwards near the vertical rib of the swingarm and measure the chain tension A Info The upper chain sect...

Page 65: ... rear sprocket bearings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check the chain tension and correct if necessary Preliminary ...

Page 66: ... markings on the left and right chain adjusters 4 are in the same position relative to the reference marks C The rear wheel is then correctly aligned Info The upper chain section must be taut Chain wear is not always even Repeat this measurement at different chain posi tions Tighten nuts 2 Make sure that the chain adjusters 4 are installed correctly on adjusting screws 3 Tighten nut 1 Guideline Nu...

Page 67: ...ket and engine sprocket 100132 10 Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Replace the rear sprocket or engine sprocket x Info The engine sprocket rear sprocket and chain should always be replaced together ...

Page 68: ... section Info Chain wear is not always even Repeat this measurement at different chain posi tions Maximum distance B at the longest chain section 272 mm 10 71 in If the distance B is greater than the specified measurement Replace the chain x Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out faster on old worn sprockets For safety reaso...

Page 69: ... 10 Nm 7 4 lbf ft Loctite 243 10 12 Adjusting the basic position of the clutch lever Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply force D...

Page 70: ... B00944 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 Check the fluid level Fluid level below container rim 4 mm 0 16 in If the coolant level does not meet specifications Correct the fluid level of the hydraulic clutch Hydraulic fluid 15 p 157 Position the cover with the membrane Mount and tighten the screws ...

Page 71: ...e wheels when driving straight ahead without the influence of lateral forces The ABS operates with two independent brake circuits front and rear brakes During nor mal operation the brake system operates like a conventional brake system without ABS When the ABS control unit detects a locking tendency in a wheel ABS begins regulating the brake pressure The regulating process causes a slight pulsing ...

Page 72: ...djusting the basic position of the hand brake lever B00945 10 Adjust the basic position of the hand brake lever to your hand size by turning adjusting wheel 1 Info Pull the brake lever forward and turn the adjusting wheel Do not make any adjustments while riding 11 3 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc s Change the worn brake disc ...

Page 73: ... deformation are visible on the brake disc Replace the brake disc 11 4 Checking the brake fluid level of the front brake Warning Danger of accidents Brake system failure If the brake fluid level drops below the specified marking or the specified value this is an indication that the brake system is leaking or that the brake linings are completely worn down Check the brake system and do not continue...

Page 74: ...linings are completely worn down Check the brake system and do not continue riding Your autho rized 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 wi...

Page 75: ...luid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container B00948 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 Add brake fluid to level A Guideline Level A brake fluid level below con tainer rim 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 155 ...

Page 76: ...e discs are rendered unserviceable Check the brake linings regularly B00947 01 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 front brake linings x Check the brake linings for damage and cracking If there is wear or tearing Change the front brake linings x 11 7 Checking the free travel of foot brake lever ...

Page 77: ...nts 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 free travel on foot brake lever according to specifications B00950 10 Disconnect spring 1 Remove screw 6 Loosen nut 4 and turn it back with ball joint 5 until the maximum amount of free travel is reached To adjust the basic posi...

Page 78: ...ft Loctite 243 Reconnect spring 1 11 9 Checking 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 efficien...

Page 79: ...stem 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 Warning...

Page 80: ...and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container B00952 10 Stand the vehicle upright Remove screw cap 1 with the washer and membrane 2 Add brake fluid to the MAX mark Brake fluid DOT 4 DOT 5 1 p 155 Mount the screw cap with the washer and membrane Info Clean up overflowed or spilt brake fluid immediately with water 11 11 Checking the rear brake linings...

Page 81: ...he braking effect is greatly reduced and the brake discs are rendered unserviceable Check the brake linings regularly B00953 01 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 the brake linings for damage and cracking If there is wear or tearing Change the rear brake linings x ...

Page 82: ...ake disc Pull the brake caliper carefully back from the brake disc and hang it to one side Info Do not pull the hand brake lever while the brake caliper is removed B00955 10 Loosen screws 5 and 6 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 d...

Page 83: ...k the wheel bearing for damage and wear If the wheel bearing is damaged or worn Replace the wheel bearing x Clean grease and mount the left and right spacers and the shaft seal rings Long life grease p 160 Clean screw 1 and wheel spindle 2 Lift the front wheel into the fork position it and insert the wheel spindle The arrow on the spoke points in the direction of motion Mount and tighten screw 1 G...

Page 84: ...re in contact with the brake disc and there is a pressure point Fix the hand brake lever in the activated posi tion The brake calipers straighten Tighten screws 6 Guideline Screw front brake caliper M10x1 25 45 Nm 33 2 lbf ft Loctite 243 Remove the fixation of the hand brake lever Take the motorcycle off of the front wheel stand p 57 Take the motorcycle off of the rear wheel stand p 58 B00955 11 P...

Page 85: ...e motorcycle with the rear wheel stand p 58 B00957 10 Main work Remove screw 1 and pull wheel speed sensor 2 out of the hole Remove nut 3 Remove chain adjuster 4 Pull out wheel spindle 5 to the point where the chain adjuster is no longer in contact with the adjusting screw ...

Page 86: ...Take the rear wheel carefully out of the swingarm without damaging the rim and or brake disc Info Do not operate the foot brake when the rear wheel is removed 12 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 brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Dange...

Page 87: ...eplace the wheel bearing x Remove bushing 1 Clean and grease the mating surfaces of the bushings and the shaft seal rings Long life grease p 160 Install the bushing Clean and grease the thread of the wheel spindle and nut Long life grease p 160 Clean the fixing locations on the brake caliper support and swingarm ...

Page 88: ...e adjust ing screws and tighten the nut Guideline In order for the rear wheel to be correctly aligned the markings on the left and right chain adjusters must be in the same position relative to the reference marks B Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Insert wheel speed sensor 4 into the hole Mount and tighten screw 5 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Operate the ...

Page 89: ...83 B00960 10 Main work Check bearing 1 If the bearing is damaged or worn Replace the bearings x Check rubber dampers 2 of the rear hub for damage and wear If the rubber dampers of the rear hub are damaged or worn Change all rubber dampers in the rear hub B00961 10 Lay the rear wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub To check play A hold th...

Page 90: ...erns 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 of accidents Reduced...

Page 91: ...nfo Note local national regulations concerning the minimum tread depth Minimum tread depth 2 mm 0 08 in If the tread depth is less than the minimum permissible depth Change the tires Check the age of the tires Info The tire s date of manufacture is usually part of the tire markings and is indi cated by the last four digits of the DOT marking The first two digits refer to the week of manufacture an...

Page 92: ...ing comfort and maximum tire service life 400695 01 Remove the dust cap Check the tire pressure when the tires are cold Tire air pressure solo Front 2 0 bar 29 psi Rear 2 0 bar 29 psi Tire air pressure with passenger fully loaded Front 2 0 bar 29 psi Rear 2 2 bar 32 psi If the tire pressure does not meet specifications Correct the tire pressure Mount the dust cap ...

Page 93: ...tery acid and battery gases Keep the battery away from sparks or open flames Charge only in well ventilated areas 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 Preliminary work Switch off all power consumers and switch off the engine Remove the passenger seat p 59 B00962 10 Main work ...

Page 94: ...p and out of the battery holder 13 2 Installing the battery x B00963 11 Main work Position the battery in the battery holder Info The terminals of the battery must face in the direction of travel Attach rubber band 1 Reconnect the positive cable 2 of the battery Guideline Screw battery terminal M6 2 2 Nm 1 62 lbf ft Position positive terminal cover 3 ...

Page 95: ...void contact with battery acid and battery gases Keep the battery away from sparks or open flames Charge only in well ventilated areas 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 Warning Environmental hazard The battery contains elements that are harmful to the environment Do not di...

Page 96: ...e 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 and sulfate destroying the battery The battery is ...

Page 97: ...start potential of the battery and to test the alternator With this device you cannot overcharge the battery Info Never remove lid 1 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 Subsequent work Mount the passenger seat p 60 Set the...

Page 98: ...if the wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Info The main fuse protects all power consumers of the vehicle The main fuse is under the passenger seat Preliminary work Switch off all power consumers and switch off the engine Remove the passenger seat p 59 ...

Page 99: ...is indicated by a burned out fuse wire A A reserve fuse 3 is located in the starter relay Install a new main fuse Fuse 58011109130 p 147 Tip Insert a new replacement fuse into the starter relay to have it available when needed Attach the protection covers 1 Follow up work Mount the passenger seat p 60 Set the clock p 29 ...

Page 100: ...d under the passenger seat These fuses protect the return pump and the hydraulic unit of the ABS The third fuse which protects the ABS control unit is located in the fuse box Preliminary work Switch off all power consumers and switch off the engine Remove the passenger seat p 59 B00966 10 To change the fuse of the ABS hydraulic unit Take off the protection cover and remove fuse 1 Insert a new fuse...

Page 101: ...Mount the protection cover Follow up work Mount the passenger seat p 60 13 6 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located on the right under the fuel tank Preliminary work Switch off all power consumers and switch off the engine B00967 10 Main work Remove screw 1 Take off cover 2 ...

Page 102: ...rol unit Fuse 3 10 A fuel pump Fuse 4 10 A radiator fan Fuse 5 10 A horn brake light turn signal alarm system optional Fuse 6 15 A high beam low beam parking light tail light license plate lamp Fuse 7 10 A for auxiliary equipment permanent positive Fuse 8 10 A for auxiliary equipment accessories connected with ignition switch Fuse 9 10 A ABS Fuse 10 not used Fuse SPARE 10 A 15 A spare fuses Info A...

Page 103: ...or repair fuses Use spare fuses with the correct rating only Fuse 75011088010 p 147 Fuse 75011088015 p 147 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 B00967 10 Position cover 2 Mount and tighten screw 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 104: ... 13 7 Removing the headlight mask with the headlight B00972 10 Switch off all power consumers and switch off the engine Remove screws 1 B00977 10 Fold the headlight mask forward Disconnect plug 2 Set down the headlight mask ...

Page 105: ...crews 2 Guideline Screw headlight EJOT 2 Nm 1 5 lbf ft Remaining screws chassis M5 5 Nm 3 7 lbf ft Check that the lighting is functioning properly 13 9 Changing the headlight bulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting ...

Page 106: ...00973 10 Main work Disconnect connector 1 Take off rubber cap 2 B00974 10 Detach retaining clamp 3 Remove bulb 4 Position the new bulb in the headlight housing Headlight H4 socket P43t p 147 Info Insert the headlight bulb so that the bayonet lugs latch into the slots Attach retaining clamp 3 ...

Page 107: ...the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preliminary work Remove the headlight mask with the headlight p 102 B00975 10 Main work Pull cable guide 1 and the socket of parking light 2 carefully out of the housing Remove the bulb Position a new light bulb in the socket Parking light W5W socket W2 1x9 5d p 147 Carefully position socket 2 with...

Page 108: ...e turn signal housing Remove diffuser 1 Press the bulb carefully into the socket turn it counterclockwise by about 30 and pull it out of the socket Info Do not touch the reflector with your fingers and keep it free from grease Press the new bulb carefully into the socket and turn it clockwise until it stops Turn signal RY10W socket BAU15s p 147 Position the diffuser Insert the screw and turn it co...

Page 109: ... 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 if applicable If the boundary between light and dark...

Page 110: ...e with rider and with luggage and a passenger if applicable the light dark boundary must be exactly on the lower mark applied in Checking the headlight setting Info Turn counterclockwise to increase the headlight range turn clockwise to reduce the headlight range If you have a payload you may have to correct the headlight range ...

Page 111: ...ure without causing any malfunctions 125 C 257 F 100167 10 Cooling takes place by means of the air stream and a radiator fan 4 which is controlled by a thermoswitch The lower the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect 14 2 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation the coolant gets very hot and is un...

Page 112: ...ach of children Condition The engine is cold Preliminary work Stand the motorcycle upright on a horizontal surface B01001 10 Main work Remove radiator cap 1 and plug 2 from the compensating tank Check the coolant antifreeze 25 45 C 13 49 F If the coolant antifreeze does not meet specifications Correct the coolant antifreeze Check the coolant level in the compensating tank The coolant level must be...

Page 113: ...se of the loss Alternative 1 Coolant p 155 Alternative 2 Coolant mixed ready to use p 155 If you had to add more coolant than the specified amount 0 50 l 0 53 qt Fill bleed the cooling system x p 114 Mount radiator cap 1 14 3 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 r...

Page 114: ...e reach of children Condition The engine is cold The radiator is completely full Preliminary work Park the motorcycle on a horizontal surface B00982 10 Main work Check the coolant level in the compensating tank 1 The coolant level must be at marking MIN If the coolant in the compensating tank is not at the required level but the tank is not empty Remove the compensating tank cap Add coolant to the...

Page 115: ...e 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 Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor i...

Page 116: ...14 5 Filling bleeding the cooling system x Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact wi...

Page 117: ... level in the compensating tank p 111 Danger Danger of poisoning Exhaust gases are poisonous 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 run it until the 5th bar of the temperature indic...

Page 118: ... with marking 2 Set the Map Select switch to Soft Set the adjusting wheel to position 1 Soft Homologized performance with very gentle response Set the Map Select switch to Advanced Set the adjusting wheel to position 2 Advanced Homologized performance with very direct response Set the Map Select switch to Standard Set the adjusting wheel to position 3 4 5 6 7 8 9 or 0 Standard Homologized performa...

Page 119: ...ine distance A between the upper edge of your boot and the shift lever Distance between shift lever and upper edge of boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the basic position of the shift lever x p 117 15 3 Adjusting the basic position of the shift lever x B00996 10 Remove screw 1 and remove shift lever 2 ...

Page 120: ...ever on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle components during the shift procedure Mount and tighten the screw Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 222 ...

Page 121: ...ning 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 Drain the engine oil only when the engine is warm B00987 10 Main work Stand the motorcycle on its side stand on a horizontal surface Place a suitable container under the engine Remove the oil drain plug 1 with ...

Page 122: ...arts and sealing area B00990 10 Remove screws 5 Remove the oil filter cover 6 with the O ring Pull oil filter 7 out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing area B00991 10 Insert the oil filter Oil the O rings of the oil filter covers Mount oil filter covers 3 and 6 Mount and tighten the screws Guideline Scr...

Page 123: ...roughly clean the parts and sealing area B00993 10 Remove plug bk with oil screen bl and the O rings Completely drain the remaining engine oil Thoroughly clean the parts and sealing area B01002 10 Position the oil screen with the O rings Mount and tighten screw plug 8 with the O ring Guideline Plug oil screen M20x1 5 15 Nm 11 1 lbf ft ...

Page 124: ... ring Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Info Too little engine oil or poor quality engine oil results in premature wear to the engine B00995 10 Remove the oil filler plug bm with the O ring from the clutch cover and fill up with engine oil Engine oil 1 70 l 1 8 qt Engine oil SAE 10W 60 00062010035 p 156 Alternative engine oil Engine oil SAE 10W 50 p 156 Install and tig...

Page 125: ... it is oil tight Follow up work Check the engine oil level p 123 16 2 Checking the engine oil level Info The engine oil level must be checked at normal engine operating temperature Condition The engine is at operating temperature B00986 01 Stand the motorcycle upright on a horizontal surface Check the engine oil level Info After switching off the engine wait one minute before checking the level Th...

Page 126: ...rformance of the engine oil do not mix different types of engine oil If appropriate change the engine oil Install and tighten the oil filler plug 1 with the O ring Danger Danger of poisoning Exhaust gases are poisonous 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 enclos...

Page 127: ... 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 Close off the exhaust system to keep water from entering First remove coarse dirt particles with a gentle spray of water Spray very dirty areas with a normal mot...

Page 128: ...e engine and on the brakes to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 61 Treat bare metal parts except for brake discs and exhaust system with anti corrosion materials Cleaning and preserving materials for metal rubber and plastic p 159 Treat all painted parts with a mild paint polish High luster polish for paint p 159 Treat all plast...

Page 129: ...ean the brakes Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts are cooled down and while they are installed After use on salted roads clean the motorcycle thoroughly with cold water and dry it properly Treat the engine the swingarm and all other bare or galvanized parts except brake dis...

Page 130: ...ble so that you can fill up with fresh fuel when you put the motorcycle back into operation Clean the motorcycle p 125 Change the engine oil and filter clean the oil screens x p 119 Check the antifreeze and coolant level p 109 Check the tire pressure p 90 Remove the battery x p 91 Recharge the battery x p 93 Guideline Storage temperature of battery without direct sunshine 0 35 C 32 95 F Store the ...

Page 131: ...not warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 18 2 Preparing for use after storage 401059 01 Take the motorcycle off of the front wheel stand p 57 Take the motorcycle off of the rear wheel stand p 58 Recharge the battery x p 93 Install the battery x p 92 Set the clock p 29 Refuel p 52 Perform checks and vehicle care when prep...

Page 132: ...ral Engine turns but does not start Operating error Carry out the start procedure p 44 Fuse 3 blown Change the fuses of individual power consumers p 99 Coupling of fuel hose connection not connected Reconnect coupling of fuel hose connection Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x Throttle opened while starting When starting DO NOT open the throt...

Page 133: ...lights flashes Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x N The idle indicator lamp does not light up when the transmission is in neutral Gear position sensor not programmed Read out the fault memory using the KTM diag nostics tool x Engine dies during the trip Lack of fuel Refuel p 52 Fuse 1 2 or 3 blown Change the fuses of individual power consume...

Page 134: ...rake light and horn are not functional Fuse 5 blown Change the fuses of individual power consumers p 99 Time is not correctly displayed Fuse 1 blown Change the fuses of individual power consumers p 99 Set the clock p 29 Battery discharged Ignition not switched off when vehicle was parked Recharge the battery x p 93 Battery is not charged by alternator Check the charging voltage x Check the quiesce...

Page 135: ...ing lamp MIL 12 FI warning lamp MIL flashes 1x long 2x short Error level condition Engine coolant temperature sensor input signal too low Engine coolant temperature sensor input signal too high Blink code of FI warning lamp MIL 13 FI warning lamp MIL flashes 1x long 3x short Error level condition Intake air temperature sensor input signal too low Intake air temperature sensor input signal too high...

Page 136: ...Error level condition Lambda sensor cylinder 1 sensor 1 circuit fault Blink code of FI warning lamp MIL 22 FI warning lamp MIL flashes 2x long 2x short Error level condition Gear position sensor circuit fault Blink code of FI warning lamp MIL 24 FI warning lamp MIL flashes 2x long 4x short Error level condition System voltage circuit fault Blink code of FI warning lamp MIL 25 FI warning lamp MIL f...

Page 137: ...Blink code of FI warning lamp MIL 37 FI warning lamp MIL flashes 3x long 7x short Error level condition Ignition coil 1 cylinder 1 circuit fault Blink code of FI warning lamp MIL 39 FI warning lamp MIL flashes 3x long 9x short Error level condition Ignition coil 2 cylinder 1 circuit fault Blink code of FI warning lamp MIL 41 FI warning lamp MIL flashes 4x long 1x short Error level condition Fuel p...

Page 138: ...o ground or open circuit Exhaust air injection valve short circuit to plus Blink code of FI warning lamp MIL 65 FI warning lamp MIL flashes 6x long 5x short Error level condition E PROM Fault Blink code of FI warning lamp MIL 82 FI warning lamp MIL flashes 8x long 2x short Error level condition Throttle position sensor circuit A input signal too high Throttle position sensor circuit A input signal...

Page 139: ...l too low Accelerator position sensor circuit A input signal too high Blink code of FI warning lamp MIL 86 FI warning lamp MIL flashes 8x long 6x short Error level condition Accelerator position sensor circuit B input signal too high Blink code of FI warning lamp MIL 87 FI warning lamp MIL flashes 8x long 7x short Error level condition Accelerator position sensor circuit A and B plausibility fault...

Page 140: ... stuck in inactive DBW throttle actuator control internal motor stuck in active Blink code of FI warning lamp MIL 92 FI warning lamp MIL flashes 9x long 2x short Error level condition DBW throttle actuator control IC stuck open Blink code of FI warning lamp MIL 93 FI warning lamp MIL flashes 9x long 3x short Error level condition CPU mutual surveillance error Blink code of FI warning lamp MIL 94 F...

Page 141: ...ning lamp MIL flashes 9x long 5x short Error level condition DBW stopping control B Blink code of FI warning lamp MIL 96 FI warning lamp MIL flashes 9x long 6x short Error level condition System voltage input signal too low System voltage input signal too high ...

Page 142: ...0028 0 0051 in Crankshaft bearing 2 roller bearings Conrod bearing Needle bearing Piston pin bearing Piston pin with DLC coating Pistons Forged light alloy Piston rings 1 L ring 1 tapered compression piston ring 1 oil scraper ring Engine lubrication Semi dry sump lubrication system with two rotor pumps Primary transmission 36 79 Clutch APTC Antihopping clutch in oil bath hydraulically operated Tra...

Page 143: ...k plug NGK LMAR7A 9 Spark plug electrode gap 0 9 mm 0 035 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 550 1 650 rpm Starting aid Electric starter automatic decompressor 21 1 Capacity engine oil Engine oil 1 70 l 1 8 qt Engine oil SAE 10W 60 00062010035 p 156 Alternative engine oil Engine oil SAE 10W 50 p 156 21 2 Capacity coolant Coolant 1 20 l 1 27 qt Cool...

Page 144: ...l filter cover M5x16 6 Nm 4 4 lbf ft Screw oil pump cover top M5 6 Nm 4 4 lbf ft Loctite 243 Cylinder head screw M6x25 10 Nm 7 4 lbf ft Loctite 243 Plug vacuum connection M6 10 Nm 7 4 lbf ft Loctite 243 Remaining screws engine M6 10 Nm 7 4 lbf ft Screw alternator cover M6x25 10 Nm 7 4 lbf ft Screw alternator cover chain shaft through hole M6x25 10 Nm 7 4 lbf ft Loctite 243 Screw autodecompression ...

Page 145: ...ew starter motor M6x20 10 Nm 7 4 lbf ft Loctite 243 Screw stator M6 10 Nm 7 4 lbf ft Loctite 243 Screw thermostat case M6x20 10 Nm 7 4 lbf ft Loctite 243 Screw timing chain guide rail M6x30 10 Nm 7 4 lbf ft Loctite 243 Screw timing chain tensioning rail M6x30 10 Nm 7 4 lbf ft Loctite 243 Screw valve cover M6 10 Nm 7 4 lbf ft Screw water pump cover M6x30 10 Nm 7 4 lbf ft Screw water pump impeller M...

Page 146: ...il pressure sensor M10x1 10 Nm 7 4 lbf ft Plug drain hole of water pump M10x1 15 Nm 11 1 lbf ft Plug oil bore for oil radiator M10x1 15 Nm 11 1 lbf ft Screw unlocking of timing chain ten sioner M10x1 10 Nm 7 4 lbf ft Spark plug outside M10x1 11 Nm 8 1 lbf ft Spark plug inside M12x1 25 18 Nm 13 3 lbf ft Coolant temperature sensor on cylinder head M12x1 5 12 Nm 8 9 lbf ft Oil drain plug with magnet ...

Page 147: ... ft Loctite 243 Nut inner clutch hub M20x1 5 100 Nm 73 8 lbf ft Loctite 243 Nut primary gear M20LHx1 5 90 Nm 66 4 lbf ft Loctite 243 Plug oil screen M20x1 5 15 Nm 11 1 lbf ft Plug timing chain tensioner M20x1 5 25 Nm 18 4 lbf ft Plug oil thermostat M24x1 5 15 Nm 11 1 lbf ft Screw in alternator cover M24x1 5 8 Nm 5 9 lbf ft ...

Page 148: ...ont Disc brake with radially screwed four piston brake caliper floating brake disc Rear Disc brake with single piston brake caliper floating Brake discs diameter Front 320 mm 12 6 in Rear 240 mm 9 45 in Brake discs wear limit Front 3 6 mm 0 142 in Rear 4 5 mm 0 177 in Tire air pressure solo Front 2 0 bar 29 psi Rear 2 0 bar 29 psi Tire air pressure with passenger fully loaded Front 2 0 bar 29 psi ...

Page 149: ...m permissible rear axle load 220 kg 485 lb Maximum permissible overall weight 350 kg 772 lb Battery CBTX9 BS Battery voltage 12 V Nominal capacity 8 Ah Maintenance free Fuse 58011109115 15 A Fuse 58011109125 25 A Fuse 58011109130 30 A Fuse 75011088015 15 A Fuse 75011088010 10 A 23 1 Lighting equipment Headlight H4 socket P43t 12 V 60 55 W Parking light W5W socket W2 1x9 5d 12 V 5 W Instrument ligh...

Page 150: ...70 ZR 17 M C 58W TL Michelin Pilot Power 160 60 ZR 17 M C 69W TL Michelin Pilot Power Additional information is available in the Service section under http www ktm com 23 3 Capacity fuel Total fuel tank capacity approx 14 l 3 7 US gal Super unleaded ROZ 95 RON 95 PON 91 p 157 Fuel reserve approx 3 2 l 3 4 qt ...

Page 151: ...TECHNICAL DATA FORK 149 Fork part number 05 18 7L 19 Fork WP Suspension Up Side Down 4357 ROMA Fork length 816 3 mm 32 13 0 12 in Fork oil per fork leg 480 ml 16 23 fl oz Fork oil SAE 5 p 157 ...

Page 152: ...ORBER 150 Shock absorber part number 01 18 7L 19 Shock absorber WP Suspension 4618 with Pro Lever linkage Spring preload Standard 4 clicks Static sag 20 mm 0 79 in Riding sag 45 50 mm 1 77 1 97 in Fitted length 365 mm 14 37 in ...

Page 153: ... M5 4 Nm 3 lbf ft Screw heat guard M5 5 Nm 3 7 lbf ft Loctite 243 Screw light switch mount and emer gency OFF switch M5 3 5 Nm 2 58 lbf ft Screw plastic clamp of brake line on fork leg M5 2 Nm 1 5 lbf ft Screw pressure regulator M5 4 Nm 3 lbf ft Bolt headlight mask M6 6 3 Nm 4 65 lbf ft Loctite 243 Remaining nuts chassis M6 10 Nm 7 4 lbf ft Remaining screws chassis M6 10 Nm 7 4 lbf ft Screw ball j...

Page 154: ...t rear sprocket screw M8 35 Nm 25 8 lbf ft Loctite 2701 Remaining nuts chassis M8 25 Nm 18 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft Screw bottom triple clamp M8 15 Nm 11 1 lbf ft Screw exhaust system M8 25 Nm 18 4 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake disc M8 30 Nm 22 1 lbf ft Loctite 243 Screw front footrest bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw hand...

Page 155: ... Loctite 243 Screw foot brake lever M10 25 Nm 18 4 lbf ft Screw handlebar support M10 20 Nm 14 8 lbf ft Screw side stand M10 35 Nm 25 8 lbf ft Loctite 243 Screw subframe M10 45 Nm 33 2 lbf ft Loctite 243 Screw top shock absorber M10 50 Nm 36 9 lbf ft Loctite 243 Banjo bolt brake line M10x1 22 Nm 16 2 lbf ft Screw front brake caliper M10x1 25 45 Nm 33 2 lbf ft Loctite 243 Lambda sensor M12x1 25 25 ...

Page 156: ...TECHNICAL DATA CHASSIS TIGHTENING TORQUES 154 Screw front wheel spindle M24x1 5 45 Nm 33 2 lbf ft Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Steering head nut M28x1 12 Nm 8 9 lbf ft ...

Page 157: ...x products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant also in countries with high temperatures Use of low quality antifreeze can lead to corrosion and foaming KTM recommends Motorex products Mixture ratio Antifreeze protection 25 45 C 13 49 F 50 corrosion inhibitor antifreeze 50 distilled water Coolant mixed ready to us...

Page 158: ...he corresponding properties KTM recommends Motorex products Synthetic engine oil Supplier Motorex Motorex KTM Cross Power 4T Engine oil SAE 10W 50 According to JASO T903 MA p 161 SAE p 161 SAE 10W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties KTM recommends Motorex products Fully syntheti...

Page 159: ...According to ISO VG 15 Guideline Use only hydraulic oil that complies with the specified standard see specifications on the container and that possesses the corre sponding properties KTM recommends Motorex products Supplier Motorex Hydraulic Fluid 75 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent...

Page 160: ...SUBSTANCES 158 Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 ...

Page 161: ...for road use Guideline KTM recommends Motorex products Supplier Motorex Chainlube Road Cleaning and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Supplier Motorex Protect Shine High luster polish for paint Guideline KTM recommends Motorex products Supplier Motorex Moto Polish ...

Page 162: ...r Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean Polish Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Synthetic ...

Page 163: ...ce intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines With 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 164: ...74 rear brake checking 78 Brakes 49 Brakes applying 49 C Chain checking 65 cleaning 61 dirt checking for 60 Chain tension adjusting 63 checking 62 Chassis number 16 Clutch fluid level checking correcting 68 Clutch lever 19 basic position adjusting 67 Combination instrument 24 clock setting 29 coolant temperature indicator 32 display 26 function buttons 24 GEAr display 32 indicator lamps 25 kilomet...

Page 165: ...e number 16 Engine oil adding 124 changing 119 Engine oil level checking 123 Engine sprocket checking 65 Environment 9 F Filler cap closing 34 opening 33 Filling up fuel 52 Foot brake lever 37 basic position adjusting 75 free travel checking 74 Fork part number 17 Front wheel installing 81 removing 80 Fuel oils etc 7 Fuse individual power consumers changing 99 Fuses ABS changing 98 H Hand brake le...

Page 166: ... the front wheel stand 57 raising with the rear wheel stand 58 taking off of the front wheel stand 57 taking off of the rear wheel stand 58 O Oil filter changing 119 Oil screens cleaning 119 Owner s manual 10 P Parking 51 Parking light bulb changing 105 Passenger footrests 36 Passenger seat mounting 60 removing 59 Preparing for use advice on first use 39 after storage 129 checks and vehicle care w...

Page 167: ...ock 23 Stopping 51 Storage 128 T Tachometer 25 Technical data chassis 146 148 chassis tightening torques 151 154 engine 140 141 engine tightening torques 142 145 fork 149 shock absorber 150 Throttle grip 20 Tire air pressure checking 90 Tire condition checking 88 Tool set 35 Transport 8 Troubleshooting 130 132 Turn signal bulb changing 106 Turn signal switch 21 Type label 16 U Use definition 7 V V...

Page 168: ...INDEX 166 Work rules 8 ...

Page 169: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 01 2012 Photo Mitterbauer 3211788en 3211788en ...

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