KTM 790 Adventure 2019 Page 185 Owner'S Manual Download | Manualshive

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SERVICE WORK ON THE CHASSIS 13

183

13.9

Checking the chain tension

Warning

Danger of accidents

Incorrect chain tension damages components and results in accidents.

If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear
wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the
rear wheel locks or the engine will be damaged.

–

Check the chain tension regularly.

–

Set the chain tension in accordance with the specification.

Preparatory work

–

Raise motorcycle with rear lifting gear. (

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Summary of Contents for 790 Adventure 2019

Page 1: ...OWNER S MANUAL 2019 790 Adventure R Art no 3213919en...

Page 2: ......

Page 3: ...wever minor differences due to further developments in design cannot be ruled out completely All specifications contained herein are non binding KTM Sportmotorcycle GmbH specifically reserves the righ...

Page 4: ...SO 9001 12 100 6061 KTM applies quality assurance processes that lead to the highest possible product quality as defined in the ISO 9001 international quality management standard Issued by T V Managem...

Page 5: ...18 3 3 Spare parts accessories 18 3 4 Service 19 3 5 Figures 19 3 6 Customer service 19 4 VIEW OF VEHICLE 22 4 1 View of vehicle front left example 22 4 2 View of vehicle rear right example 24 5 SERIA...

Page 6: ...artment on the right 48 6 16 Tool set 49 6 17 Grab handles 49 6 18 Luggage rack plate 50 6 19 Seat lock 51 6 20 Passenger foot pegs 51 6 21 Shift lever 52 6 22 Foot brake lever 53 6 23 Side stand 53 7...

Page 7: ...Throttle Response 101 7 24 20 Leave Rally 102 7 24 21 Motorcycle 103 7 24 22 MTC 103 7 24 23 ABS 104 7 24 24 Quick Shift optional 105 7 24 25 Settings 106 7 24 26 Favorites 106 7 24 27 Quick Selector...

Page 8: ...ing the vehicle 143 10 3 Starting off 144 10 4 Quickshifter optional 145 10 5 Shifting riding 146 10 6 Applying the brakes 152 10 7 Stopping parking 155 10 8 Transporting 157 10 9 Refueling 158 11 SER...

Page 9: ...ght side cover 194 13 16 Removing the battery cover 195 13 17 Installing the battery cover 196 13 18 Removing left fuel tank spoiler 197 13 19 Installing the left fuel tank spoiler 200 13 20 Removing...

Page 10: ...SYSTEM 261 16 1 Daytime running light DRL 261 16 2 Removing the 12 V battery 262 16 3 Installing the 12 V battery 266 16 4 Charging the 12 V battery 269 16 5 Changing the main fuse 273 16 6 Changing t...

Page 11: ...HNICAL DATA 315 23 1 Engine 315 23 2 Engine tightening torques 317 23 3 Capacities 323 23 3 1 Engine oil 323 23 3 2 Coolant 323 23 3 3 Fuel 323 23 4 Chassis 324 23 5 Electrical system 326 23 6 Tires 3...

Page 12: ...ith this symbol requires specialist knowledge and technical understanding In the interest of your own safety have these jobs performed by an authorized KTM workshop Your motorcycle will be optimally c...

Page 13: ...rework 1 2 Formats used The typographical formats used in this document are explained below Proprietary name Indicates a proprietary name Name Indicates a protected name Brand Indicates a brand availa...

Page 14: ...to advise you 2 2 Misuse The vehicle must only be used as intended Dangers can arise for people property and the environment through use not as intended Any use of the vehicle beyond the intended and...

Page 15: ...nvariably lead to fatal or serious permanent injury if the appropriate measures are not taken Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures...

Page 16: ...rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below 1 Removal or puncturing of the main silencers baffles header pipes or any other component...

Page 17: ...the exhaust system radiator engine shock absorber or brake system before the vehicle parts have cooled down Let the vehicle parts cool down before you perform any work on the vehicle Only operate the...

Page 18: ...hing 2 8 Work rules Special tools are necessary for certain tasks The tools are not a component of the vehicle but can be ordered using the number in parentheses Example bearing puller 15112017000 Dur...

Page 19: ...advise you 2 10 Owner s Manual It is important that you read this Owner s Manual carefully and completely before making your first trip The Own er s Manual contains useful information and many tips o...

Page 20: ...d in the Service Warranty Booklet 3 2 Fuel auxiliary substances Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil o...

Page 21: ...nents such as the drive train brake system or suspension components For this reason it may be necessary to inspect or replace parts before the next scheduled service It is imperative that you adhere t...

Page 22: ...3 IMPORTANT NOTES 20 A list of authorized KTM dealers can be found on the KTM website International KTM Website http www ktm com...

Page 23: ...IMPORTANT NOTES 3 21...

Page 24: ...4 VIEW OF VEHICLE 22 4 1 View of vehicle front left example F02001 10...

Page 25: ...or electrical accessories p 42 2 Clutch lever p 31 3 Seat lock p 51 4 Storage compartment on the left 5 Grab handles p 49 6 Luggage rack plate p 50 7 Passenger foot pegs p 51 8 Rider footrests 9 Shift...

Page 26: ...4 VIEW OF VEHICLE 24 4 2 View of vehicle rear right example F02002 10...

Page 27: ...n the right 2 Light switch p 33 2 Menu switch p 37 2 Turn signal switch p 37 2 Horn button p 38 3 Fuel tank filler cap 4 Emergency OFF switch electric starter button p 39 5 Hand brake lever p 31 6 Eng...

Page 28: ...5 SERIAL NUMBERS 26 5 1 Vehicle identification number 402324 10 The vehicle identification number 1 is stamped on the right side of the steering head...

Page 29: ...SERIAL NUMBERS 5 27 5 2 Type label F01880 10 The type label 1 is located on the frame on the left The type label for Australia 2 is located on the frame on the right...

Page 30: ...01200 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 5 4 Engine number H01047 10 The engine number 1 is stam...

Page 31: ...5 5 Fork part number 402295 10 The fork part number 1 is stamped on the inner side of the fork stub 5 6 Shock absorber article number 402339 10 Shock absorber article number 1 is attached the top of...

Page 32: ...5 SERIAL NUMBERS 30 5 7 Steering damper article number F01881 10 Steering damper article number 1 is embossed on the underside of the steering damper...

Page 33: ...lever F02004 10 Clutch lever 1 is fitted on the handlebar on the left 6 2 Hand brake lever F02005 10 The hand brake lever 1 is fitted on the right side of the handle bar The front brake is engaged us...

Page 34: ...tle grip F02006 10 The throttle grip 1 is fitted on the right side of the handlebar 6 4 Switches on the left side of the handlebar 6 4 1 Combination switch The combination switch is fitted on the left...

Page 35: ...F01886 10 The light switch 1 is fitted on the combination switch on the left Possible states Low beam on Light switch in position A In this position the low beam and tail light are switched on High b...

Page 36: ...ss cruise control system tip switch at the top The last saved speed is reached and maintained Every sub sequent brief pressing increases the target speed by 1 km h or 1 mph Press and hold cruise contr...

Page 37: ...em function press the cruise control system tip switch to the left In addition the cruise control system function is deactivated when one of the following events occurs Operating the hand brake lever...

Page 38: ...lippery road surfaces e g rain ice or snow or unpaved surfaces e g sand stones or gravel Do not use the cruise control systems function if the traffic does not permit a constant speed The cruise contr...

Page 39: ...ton 3 is the SET button Button 4 is the BACK button 6 4 5 Turn signal switch F02008 11 Turn signal switch 1 is fitted on the combination switch on the left Possible states Turn signal off Left turn si...

Page 40: ...the turn signal switch towards the switch case 6 4 6 Horn button F02008 12 The horn button 1 is fitted on the combination switch on the left Possible states Horn button in neutral position Horn butto...

Page 41: ...states Emergency OFF switch electric starter button off top position In this position the ignition circuit is inter rupted a running engine stops and a non running engine cannot be started A message...

Page 42: ...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...

Page 43: ...nto the ignition and steering lock press in and turn to the left Remove the ignition key Steering is no longer possible 6 8 Unlocking the steering 400731 01 Insert the ignition key into the ignition a...

Page 44: ...cur rent consump tion 10 A 6 10 Opening the fuel tank filler cap Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the...

Page 45: ...clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Note Environmental hazard Improper handling of fuel is a danger to the environment...

Page 46: ...cap and turn the ignition key counterclockwise until the lock closes Warning Fire hazard Fuel is highly flammable toxic and a health hazard Check that the fuel tank filler cap is locked cor rectly aft...

Page 47: ...6 12 Opening the storage compartment on the left Preparatory work Remove the seat p 179 Remove the left side cover p 191 F02012 10 Main work Lift the elastic fastener 1 and detach in area A Open stora...

Page 48: ...13 Closing the storage compartment on the left F02013 10 Main work Close the storage compartment Raise elastic fastener 1 and hang up in area A Finishing work Install the left side cover p 192 Mount...

Page 49: ...14 Opening the storage compartment on the right Preparatory work Remove the seat p 179 Remove the right side cover p 193 F02014 10 Main work Lift the elastic fastener 1 and detach in area A Open stor...

Page 50: ...15 Closing the storage compartment on the right F02015 10 Main work Close the storage compartment Raise elastic fastener 1 and hang up in area A Finishing work Install the right side cover p 194 Mount...

Page 51: ...left or right storage compartment contains the on board tool set 1 6 17 Grab handles F02017 10 The grab handles 1 are used for moving the motorcycle around If you carry a passenger the passenger can h...

Page 52: ...seat The base plate of a luggage system can be mounted on the lug gage rack plate optional The luggage rack plate may not be loaded with more than the specified weight Maximum permissi ble load on lu...

Page 53: ...he vehicle It can be unlocked using the ignition key 6 20 Passenger foot pegs F02019 10 The passenger foot pegs can be folded up and down Possible states Passenger foot pegs folded up For operation wi...

Page 54: ...OLS 52 6 21 Shift lever V01271 11 Shift lever 1 is mounted on the left of the engine V01271 10 The gear positions can be seen in the figure The neutral or idle position is between the first and second...

Page 55: ...29 10 The side stand 1 is located on the left of the vehicle The side stand is used for parking the motorcycle Info The side stand must be folded up during motorcycle use The side stand is coupled wit...

Page 56: ...6 CONTROLS 54 Side stand folded in This position is mandatory when riding the motorcycle The safety starting system is inactive...

Page 57: ...tion areas 1 indicator lamps p 60 Display 2 7 2 Activation and test F01764 01 Activation The combination instrument is activated when the ignition is switched on Info The brightness of the displays is...

Page 58: ...rs in the pro cess and contact an authorized KTM workshop The oil pressure warning lamp always lights up as long as the engine is not running If the engine is running and the oil pressure warning lamp...

Page 59: ...light sensor in the combination instrument measures the brightness of the environment The display is brightened darkened or switched to the other mode depending on the light intensity measured by the...

Page 60: ...which require immediate intervention Info Warnings can be hidden by pressing any button All the existing warnings are displayed in the Warning sub menu until they are no longer active 7 5 Ice warning...

Page 61: ...COMBINATION INSTRUMENT 7 59 Info When the ice warning lights up the warning ICE WARN ING also appears...

Page 62: ...7 COMBINATION INSTRUMENT 60 7 6 Indicator lamps F01768 01...

Page 63: ...s run ning and the oil pressure warning lamp lights up stop immediately taking care not to endanger yourself or other road users in the process and switch off the engine The ABS warning lamp and TC in...

Page 64: ...cess and switch off the engine The alarm system indicator lamp lights up or flashes red Status or error message of the alarm system The cruise control system indicator lamp optional lights up yellow T...

Page 65: ...COMBINATION INSTRUMENT 7 63...

Page 66: ...7 COMBINATION INSTRUMENT 64 7 7 Display F01769 10...

Page 67: ...meter p 69 5 Unit for the speedometer 6 Cruise control indicator optional p 70 7 Ride display p 71 8 ABS display p 71 9 MTC display p 72 bk Coolant temperature indicator p 72 bl Fuel level display p 7...

Page 68: ...7 COMBINATION INSTRUMENT 66 7 8 RALLY display F01770 10...

Page 69: ...reen of the combination instrument in active drive mode RALLY If the menu is opened the speed is still displayed 1 Driving mode RALLY 2 ABS mode 3 Throttle Response p 293 4 Slip adjustment p 293 7 9 S...

Page 70: ...hift warn ing light can only be deactivated and the values for Lights up and Flashes can only be adjusted after this In Lights up the shift warn ing light flashes and in Flashes it flashes and the col...

Page 71: ...MENT 7 69 Flashes shift warning light flashes and changes color 7 11 Speedometer F01773 01 Speed is shown in kilometers per hour km h or in miles per hour mph The unit of speed can be configured in th...

Page 72: ...isplay Cruise control is operated using the cruise control tip switch p 34 Info If the cruise control system function is switched on but cruise control is not activated the cruise control system indic...

Page 73: ...0 The Ride Mode p 291 setting is shown in area 1 of the dis play The drive mode can be configured in the Ride Mode submenu 7 14 ABS display F01775 11 The ABS mode setting is shown in the 1 area of the...

Page 74: ...tched on or off The motorcycle traction control can be switched on or off in the MTC submenu 7 16 Coolant temperature indicator F01776 01 The coolant temperature indicator consists of bars The more ba...

Page 75: ...nd cooling system to cool down Check and if necessary correct the coolant level on the cool ing system while it is in a cooled state Info When all the bars flash the warning ENGINE TEMP HIGH also appe...

Page 76: ...getting low the last segment flashes red and the following warning LOW FUEL also appears The fuel level is displayed with a slight delay to prevent the indicator from constantly moving while riding Th...

Page 77: ...an be configured in the Temperature submenu 7 19 Time F01779 01 The time is displayed in 24 hour format in all languages except for EN US The time is displayed in 12 hour format if the language is set...

Page 78: ...information selected are displayed on two lines Five to eight items of information selected are displayed on a single line 7 21 Quick Selector 1 display F01781 01 When the menu is closed the Quick Sel...

Page 79: ...r 2 submenu Any information can be selected 7 23 Navigation display optional F01783 01 The Navigation display appears when the navigation function is active In the Navigation display the direction arr...

Page 80: ...4 1 KTM MY RIDE optional F01785 01 Condition The motorcycle is stationary Function KTM MY RIDE optional activated Function Bluetooth optional activated Press the SET button when the menu is closed Pre...

Page 81: ...tivated The combination instrument is connected to a suitable cell phone The combination instrument is connected to a suitable head set Press the SET button when the menu is closed Press the UP or DOW...

Page 82: ...ss the UP button briefly to change to the next audio track Briefly pressing the DOWN button twice changes to the previ ous audio title or plays the current audio title depending on the cellphone model...

Page 83: ...to a suitable cell phone The GPS function is activated on the connected cellphone For voice navigation The combination instrument is connected to a suitable headset and an appropriate language package...

Page 84: ...trument 7 24 4 Navigation Setup optional F01788 01 Condition Function KTM MY RIDE optional activated The KTM MY RIDE app optional is installed and opened on a suitable cellphone Android devices Versio...

Page 85: ...the menu item using the UP or DOWN button Press the SET button to switch the visual navigation on or off Info Voice navigation remains switched on if it has been activated 7 24 5 Volume optional F018...

Page 86: ...he UP or DOWN button until Navigation is marked Press the SET button to open the submenu Warning Danger of accidents Headphone volume which is too high distracts attention from traffic activity Always...

Page 87: ...the UP or DOWN button until Pairing is marked Press the SET button to open the submenu A suitable cellphone or headset can be paired with the combina tion instrument via Bluetooth in the Pairing subm...

Page 88: ...RIDE is marked Press the SET button to open the menu Press the UP or DOWN button until Pairing is marked Press the SET button to open the submenu Press the UP or DOWN button until Phone is marked Pre...

Page 89: ...onfirming the Passkey on the cellphone and on the combination instrument Info Once the pairing is completed the name of the paired cellphone is displayed in the Phone submenu Press the UP or DOWN butt...

Page 90: ...n KTM MY RIDE optional activated Function Bluetooth optional activated The Bluetooth function should also be activated in the device to be paired Press the SET button when the menu is closed Press the...

Page 91: ...ring mode for the headset to be found by the combination instrument Follow the instructions in the Owner s Manual of the headset Once the pairing is completed the name of the paired headset is display...

Page 92: ...is not automatically paired with the combina tion instrument after approx 30 seconds Restart the combination instrument or repeat the Pair ing procedure A suitable headset can be paired with the comb...

Page 93: ...phone The combination instrument is connected to a suitable head set Warning Danger of accidents Headphone volume which is too high distracts attention from traffic activity Always select headphone v...

Page 94: ...ame An incoming call is visualized in a small window at the top of the combination instrument display when the navigation function is active You cannot navigate in the menu during an active phone conv...

Page 95: ...ess the SET button to open the menu Press the UP or DOWN button until General Info is marked Press the SET button to open the submenu In the submenu General Info the date total route ridden and bat te...

Page 96: ...p 1 submenu Info Trip shows the distance since the last reset such as between two refueling stops Trip is running and counts up to 9999 Cons indicates the average fuel consumption based on Trip Speed...

Page 97: ...p 2 submenu Info Trip shows the distance since the last reset such as between two refueling stops Trip is running and counts up to 9999 Cons indicates the average fuel consumption based on Trip Speed...

Page 98: ...e the necessity to check the tires before going on a ride To avoid false alarms the tire pressure values are evaluated over a period of several minutes Check the tire pressure before every ride Correc...

Page 99: ...FW indicates the tire pressure at the front RW indicates the tire pressure at the rear 7 24 15 Warning F01800 01 Condition Message or warning is present Press the SET button when the menu is closed Pr...

Page 100: ...he dis play until they are no longer active 7 24 16 Ride Mode F01831 01 Press the SET button when the menu is closed Press the UP or DOWN button until Ride Mode is marked Press the SET button to open...

Page 101: ...he UP or DOWN button Press the SET button to select the engine and motorcycle trac tion control settings that are coordinated with each other STREET homologated performance with balanced response the...

Page 102: ...dividually set The Anti Wheelie mode is deactivated Info Do not open the throttle during the selection 7 24 18 Rally F01802 01 Condition The drive mode RALLY is activated Press the SET button when the...

Page 103: ...ss the SET button to open the menu Press the UP or DOWN button until Throttle Response is marked on the display Press the SET button to open the submenu Activate menu item using the UP or DOWN button...

Page 104: ...s closed Press the UP or DOWN button until Rally is marked on the dis play Press the SET button to open the menu Press the UP or DOWN button until Leave Rally is marked on the display Press the SET bu...

Page 105: ...ontrol and the quickshifter optional can be switched on or off and the ABS can be configured 7 24 22 MTC F01806 01 Press the SET button when the menu is closed Press the UP or DOWN button until Motorc...

Page 106: ...ation of the motorcycle traction control 7 24 23 ABS F01807 01 Press the SET button when the menu is closed Press the UP or DOWN button until Motorcycle is marked Press the SET button to open the menu...

Page 107: ...ve ABS only con trols the front wheel The rear wheel is not controlled by ABS and may lock during braking maneuvers 7 24 24 Quick Shift optional F01808 01 Press the SET button when the menu is closed...

Page 108: ...configured Settings can be made for units or various values Several functions can be enabled or disabled 7 24 26 Favorites F01810 01 Condition The motorcycle is stationary Press the SET button when th...

Page 109: ...ess the UP or DOWN button until Settings is marked Press the SET button to open the menu Press the UP or DOWN button until Quick Selector 1 is marked Press the SET button to open the menu Activate the...

Page 110: ...ngs is marked Press the SET button to open the menu Press the UP or DOWN button until Quick Selector 2 is marked Press the SET button to open the menu Activate the menu item using the UP or DOWN butto...

Page 111: ...etooth is marked Press the SET button to open the submenu Activate the menu item using the UP or DOWN button Press the SET button to switch the Bluetooth function on or off Info The Bluetooth function...

Page 112: ...ttings is marked Press the SET button to open the menu Press the UP or DOWN button until Display Theme is marked Press the SET button to open the submenu Activate the menu item using the UP or DOWN bu...

Page 113: ...submenu The shift warning light can be configured in the Shift Light sub menu 7 24 32 Lights up F01815 01 Condition The motorcycle is stationary ODO 1 000 km 621 mi Press the SET button when the menu...

Page 114: ...osed Press the UP or DOWN button until Settings is marked Press the SET button to open the menu Press the UP or DOWN button until Shift Light is marked Press the SET button to open the submenu Press t...

Page 115: ...ess the SET button to open the menu Press the UP or DOWN button until Shift Light is marked Press the SET button to open the submenu Press the UP or DOWN button until Shift Light is marked Press the S...

Page 116: ...l Clock Date is marked Press the SET button to open the submenu F01819 01 Setting the clock Press UP or DOWN button until the time is marked Press the SET button The hour flashes and is underlined Pre...

Page 117: ...lashes and is underlined Press UP or DOWN button until the current day is set Press SET button The month flashes and is underlined Press UP or DOWN button until the current month is set Press the SET...

Page 118: ...ion The motorcycle is stationary Press the SET button when the menu is closed Press the UP or DOWN button until Settings is marked Press the SET button to open the menu Press the UP or DOWN button unt...

Page 119: ...ility is significantly impaired due to fog snow or rain Ensure that the appropriate type of lighting is always selected If necessary switch off the daytime running lights using the menu before going o...

Page 120: ...lows settings to be made for units or various values 7 24 38 Distance F01823 01 Condition The motorcycle is stationary Press the SET button when the menu is closed Press the UP or DOWN button until Se...

Page 121: ...til Temperature is marked Press the SET button to open the submenu Activate the menu item using the UP or DOWN button Press the SET button to confirm the desired unit 7 24 40 Fuel Cons F01825 01 Condi...

Page 122: ...T button when the menu is closed Press the UP or DOWN button until Settings is marked Press the SET button to open the menu Press the UP or DOWN button until Language is marked Press the SET button to...

Page 123: ...DOWN button until Settings is marked Press the SET button to open the menu Press the UP or DOWN button until Service is marked Press the SET button to open the submenu Use the UP or DOWN button to nav...

Page 124: ...the UP or DOWN button until Settings is marked Press the SET button to open the menu Press the UP or DOWN button until Extra Functions is marked Press the SET button to open the submenu Use the UP or...

Page 125: ...le distance B 3 5 mm 0 138 in The handlebar can be mounted in six different positions This allows the handlebar to be mounted in the most comfortable posi tion for the rider 8 2 Adjusting the handleba...

Page 126: ...es Remove screws 3 Take off handlebar supports 4 Move the handlebar supports into the desired position B A or C Mount and tighten screws 3 Guideline Mount the left and right handlebar supports in the...

Page 127: ...ERGONOMICS 8 125 Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft...

Page 128: ...S 126 8 3 Adjusting the windshield F02020 10 Alternative 1 Remove screw 1 and windshield 2 Position windshield 2 in lower recess A Mount and tighten screw 1 Guideline Remaining screws chassis M5 5 Nm...

Page 129: ...ERGONOMICS 8 127 F02021 10 Alternative 2 Remove screw 1 and windshield 2 Position windshield 2 in upper recess B Mount and tighten screw 1 Guideline Remaining screws chassis M5 5 Nm 3 7 lbf ft...

Page 130: ...size by turning adjusting screw 1 Info When the adjusting screw is turned clockwise the clutch lever moves closer to the handlebar When the adjusting screw is turned counterclockwise the clutch lever...

Page 131: ...rning adjusting screw 1 Info Turn the adjusting screw clockwise to decrease the distance between the hand brake lever and the han dlebar Turn the adjusting screw counterclockwise to increase the dista...

Page 132: ...ot brake lever stub F01946 10 Remove screws 1 with the foot brake lever stub Move the foot brake lever stub into desired position A or B Mount and tighten screws 1 Guideline Screw foot brake lever stu...

Page 133: ...there is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification F02022 10 Deta...

Page 134: ...downwards Screwing the push rod out of the ball joint adjusts the brake lever upwards F01921 10 Loosen nut 4 and turn screw 5 correspondingly until the free travel A is present If necessary adjust the...

Page 135: ...to make this eas ier Attach spring 1 8 8 Checking the basic position of the shift lever Info When driving the shift lever must not touch the rider s boot when in the basic position If the shift lever...

Page 136: ...does not meet specifications Adjust the basic position of the shift lever p 134 8 9 Adjusting the basic position of the shift lever H02668 10 Loosen nut 1 holding threaded rod 2 Loosen nut 3 holding t...

Page 137: ...ERGONOMICS 8 135 Tighten nut 3 while holding threaded rod 2 Guideline Nut shift rod M6LH 6 Nm 4 4 lbf ft Tighten nut 1 while holding threaded rod 2 Guideline Nut shift rod M6 6 Nm 4 4 lbf ft...

Page 138: ...et boots gloves as well as trousers and a jacket with protectors on all rides Always wear protective clothing that is in good condition and meets the legal regulations Warning Danger of crashing Diffe...

Page 139: ...foot off the foot brake lever when you are not braking Info When using your vehicle remember that others may feel disturbed by excessive noise Make sure that the pre sales inspection work has been car...

Page 140: ...ands and keep your feet on the footrests when riding Run the engine in p 138 9 2 Running in the engine During the running in phase do not exceed the specified engine speed Guideline Maximum engine spe...

Page 141: ...of accidents Improper mounting of cases or the tank rucksack impairs the handling characteris tic Mount and secure cases and tank rucksack according to the manufacturer s instructions Warning Danger o...

Page 142: ...to your payload Warning Danger of accidents Pieces of luggage which have slipped impair the handling characteristic Check that your luggage is fixed properly at regular intervals Warning Fire hazard T...

Page 143: ...PREPARING FOR USE 9 141 Guideline Maximum permissible total weight 450 kg 992 lb Maximum permissible front axle load 175 kg 386 lb Maximum permissible rear axle load 275 kg 606 lb...

Page 144: ...d level p 234 Check the front brake linings p 232 Check the rear brake linings p 237 Check that the brake system is functioning properly Check the coolant level in the compensating tank p 287 Check th...

Page 145: ...fespan of the engine Always run the engine warm at a low speed B00782 10 Take the motorcycle off the side stand and sit on the motorcy cle Make sure that the emergency OFF switch electric starter but...

Page 146: ...tem and the engine cannot start Press the emergency OFF switch electric starter button into the lower position for a maximum of 5 seconds Wait for a least 5 seconds before trying again This motorcycle...

Page 147: ...ere is no need to close the throttle grip uninterrupted gear shifts are possible The quickshifter uses the shifter shaft position to check whether or not a shift should be initiated and sends a corres...

Page 148: ...ng Danger of accidents If you change down at high engine speed the rear wheel blocks and the engine races Do not change into a low gear at high engine speed Warning Danger of accidents An incorrect ig...

Page 149: ...ning Danger of accidents A risky riding style constitutes a major risk Comply with traffic regulations and ride defensively and with foresight to detect sources of danger as early as possible Warning...

Page 150: ...Danger of accidents A fall can damage the vehicle more seriously than it may first appear Check the vehicle after a fall as you do when preparing for use Note Engine damage Unfiltered intake air has...

Page 151: ...er yourself or other road users in the process switch off the engine and contact an authorized KTM workshop V01271 10 Shift into a higher gear when conditions allow incline road situation etc Release...

Page 152: ...gear release the clutch lever slowly and open the throttle or shift again If the engine stalls e g at a crossroads just pull clutch lever and press emergency OFF switch electric starter button into th...

Page 153: ...peed to the road conditions H02699 10 If the quickshifter optional is enabled in the combination instrument you can shift up in the speed range shown without pulling the clutch lever Info The minimum...

Page 154: ...quickly back to the stop without changing the throttle twist grip position 10 6 Applying the brakes Warning Danger of accidents Moisture and dirt impair the brake system Brake carefully several times...

Page 155: ...nger or luggage with you Warning Danger of accidents Salt on the roads impairs the brake system Brake carefully several times to remove salt from the brake linings and the brake discs Warning Danger o...

Page 156: ...oad surfaces steep descents or full braking without disengaging the gear Adapt your riding style to the road conditions and your driving ability When braking release the throttle and apply the front a...

Page 157: ...nition key if you leave the vehicle unattended Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch any parts such as the exhaust system radiator e...

Page 158: ...ignition remains switched on at the ignition lock power continues to flow to most power consumers This discharges the 12 V battery You should therefore always switch off the engine with the ignition l...

Page 159: ...face Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk Do not park the vehicle near to materials which are highly flammable or explosive Allow the vehicle to cool down befo...

Page 160: ...lled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consul...

Page 161: ...t This will result in problems with the fuel system Refuel only with clean fuel that meets the specified standards Your authorized KTM workshop will be glad to help Note Environmental hazard Improper...

Page 162: ...ff the engine Open the fuel tank filler cap p 42 Fill the fuel tank with fuel up to the lower edge A of the filler neck Total fuel tank capacity approx 20 l 5 3 US gal Super unleaded ROZ 95 RON 95 PON...

Page 163: ...te service schedule can always be found on KTM Dealer net Your authorized KTM dealer will be happy to advise you 11 2 Required work every 24 months every 12 months every 30 000 km 18 600 mi every 15 0...

Page 164: ...the clutch lever p 302 Check the free travel of the foot brake lever p 233 Check the shock absorber and fork for leaks Perform service as needed and depending on how the vehicle is used Clean the dus...

Page 165: ...Change the air filter clean the air filter box Check the fuel pressure Check the headlight setting p 280 Check that the radiator fan is functioning properly Final check Check the vehicle is roadworth...

Page 166: ...for clutch lubrication Check the fork bearing for play Check the wheel bearing for play Change the coolant Empty the drainage hoses Check all hoses e g fuel cooling bleeder drainage hoses etc and slee...

Page 167: ...n setting are shown in table 1 The table is located under the seat on the air filter box These adjustments are guidelines and should always be the basis for a suspension setting If the guidelines are...

Page 168: ...is located in left fork leg COMP white adjuster The rebound damping is located in right fork leg REB red adjuster Turn counterclockwise by the number of clicks corresponding to the fork type Guideline...

Page 169: ...s it will go Info Adjuster 1 is located at the upper end of the right fork leg The rebound damping is located in right fork leg REB red adjuster The compression damping is located in left fork leg COM...

Page 170: ...e motorcycle with rear lifting gear p 176 Remove the front fender p 207 Lift the motorcycle with the front lifting gear p 177 F02056 10 Main work Turn the adjusting wings 1 counterclockwise all the wa...

Page 171: ...between the numerical values Turn clockwise to increase the spring preload turn counterclockwise to reduce the spring preload Adjusting the spring preload has no influence on the absorption setting o...

Page 172: ...ar wheel suspension compresses slowly These two ranges can be adjusted separately although the transition between high speed and low speed is grad ual Thus modifications in the high speed range affect...

Page 173: ...ick Info Do not loosen fitting 2 Turn the counterclockwise by the number of clicks correspond ing to the shock absorber type Guideline Low speed compression damping Comfort 20 clicks Standard 15 click...

Page 174: ...sorber is filled with highly compressed nitrogen Please follow the description provided Your authorized KTM workshop will be glad to help Info The effect of the high speed setting can be seen in fast...

Page 175: ...damping turn counterclock wise to reduce damping 12 8 Adjusting the rebound damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is d...

Page 176: ...rt 20 clicks Standard 15 clicks Sport 12 clicks Full payload 9 clicks Info Turn clockwise to increase damping turn counterclock wise to reduce damping 12 9 Adjusting the spring preload of the shock ab...

Page 177: ...ssenger thus ensuring an ideal compromise between handling and stability F02028 10 Turn adjusting screw 1 counterclockwise all the way Turn it clockwise by the number of turns corresponding to the sho...

Page 178: ...retaining adapter on the link fork Insert adapter in the rear lifting gear Retaining adapter 61029955144 Rear wheel work stand 69329955000 Stand motorcycle upright align lifting gear to the link fork...

Page 179: ...hicle on side stand 1 Remove the retaining adapter from the link fork 13 3 Lifting the motorcycle with the front lifting gear Note Danger of damage The parked vehicle can roll away or fall over Park t...

Page 180: ...stem Mounting pin 69329965040 Front wheel work stand large 69329965100 Align the front lifting gear with the fork legs Info Always raise the motorcycle at the rear first Lift the motorcycle at the fro...

Page 181: ...against falling over Remove the front lifting gear Finishing work Install the front fender p 208 13 5 Removing the seat H02022 10 Insert the ignition key in seat lock 1 and turn it clockwise Raise the...

Page 182: ...the rear and push it forward Insert locking pin 2 into the lock housing and push down the rear of the seat until the locking pin engages with a click Check that the seat is correctly mounted 13 7 Chec...

Page 183: ...es the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Note Environmental hazard Hazardous substances cause environmental dama...

Page 184: ...work Rinse off loose dirt with a soft jet of water Remove old grease residue with chain cleaner Chain cleaner p 342 After drying apply chain spray Street chain spray p 343 Finishing work Remove the r...

Page 185: ...et rear sprocket transmission and rear wheel bearings wear more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocke...

Page 186: ...he chain sliding piece 2 5 cm 0 98 in Measure the distance from the flat part of the link fork directly above the chain not from the edge of the link fork Info Top chain section C must be taut Chain w...

Page 187: ...et transmission and rear wheel bearings wear more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result...

Page 188: ...ews 3 on the left and right so that the markings on the left and right chain adjusters 4 are in the same position relative to the reference marks A The rear wheel is then correctly aligned Info The to...

Page 189: ...p 183 13 11 Checking the chain rear sprocket engine sprocket and chain guide Preparatory work Raise motorcycle with rear lifting gear p 176 100132 10 Main work Check the chain rear sprocket and engine...

Page 190: ...ction Info Chain wear is not always even Repeat this measure ment at different chain positions Maximum distance B from 18 chain rollers at the longest chain section 272 mm 10 71 in If distance B is gr...

Page 191: ...engine sprocket cover is highly worn in the marked area C Change the engine sprocket cover Check the engine sprocket cover 1 for tightness If the engine sprocket cover is loose Tighten the screws on...

Page 192: ...e chain sliding guard If the chain sliding guard is highly worn on the underside in the marked area E Change the chain sliding guard Check that the chain sliding guard is firmly seated If the chain sl...

Page 193: ...1 13 12 Removing the left side cover Preparatory work Remove the seat p 179 F02032 10 Main work Remove left side cover from the rubber bushings in the areas A and B Pull off the left side cover sidewa...

Page 194: ...3 10 Main work Position the left side cover with holding lug 1 on bushing 2 and push backward The left side cover engages under the tail part Press the left side cover in area A into rubber bushing 3...

Page 195: ...93 13 14 Removing the right side cover Preparatory work Remove the seat p 179 F02034 10 Main work Remove the side cover from the rubber bushings in areas A and B Pull off the right side cover sideways...

Page 196: ...Main work Position the right side cover with holding lug 1 on bush ing 2 and push backward The right side cover engages under the tail part Press the right side cover in the area A into rubber bush i...

Page 197: ...SERVICE WORK ON THE CHASSIS 13 195 13 16 Removing the battery cover Preparatory work Remove the seat p 179 F02044 10 Main work Remove screws 1 with the bushings Remove the battery cover from above...

Page 198: ...ork Position the battery cover with holding lugs 1 on bushings 2 and push downward The battery cover engages on the left and right under the fuel tank spoiler Mount screws 3 with the bushings and tigh...

Page 199: ...SERVICE WORK ON THE CHASSIS 13 197 13 18 Removing left fuel tank spoiler Preparatory work Remove the seat p 179 Remove the left side cover p 191 Remove the battery cover p 195...

Page 200: ...13 SERVICE WORK ON THE CHASSIS 198 F02046 10 Main work Remove screw 1 Remove screws 2...

Page 201: ...SERVICE WORK ON THE CHASSIS 13 199 F02057 10 Remove the left fuel tank spoiler from the rubber bushing in area A Pull off the left fuel tank spoiler sideways and remove it toward the front...

Page 202: ...IS 200 13 19 Installing the left fuel tank spoiler F02061 10 Main work Position the left fuel tank spoiler with holding lug 1 on bush ing 2 and push backward laterally Press the fuel tank spoiler into...

Page 203: ...et Guideline Screw fuel tank spoiler M6 5 Nm 3 7 lbf ft The front edge of the left fuel tank spoiler is evenly aligned Tighten all the screws of the left fuel tank spoiler Guideline Remaining screws c...

Page 204: ...13 SERVICE WORK ON THE CHASSIS 202 13 20 Removing right fuel tank spoiler Preparatory work Remove the seat p 179 Remove the right side cover p 193 Remove the battery cover p 195...

Page 205: ...SERVICE WORK ON THE CHASSIS 13 203 F02048 10 Main work Remove screw 1 Remove screws 2...

Page 206: ...13 SERVICE WORK ON THE CHASSIS 204 F02058 10 Remove the fuel tank spoiler from the rubber bushing in area A Pull off the right fuel tank spoiler sideways and remove it toward the front...

Page 207: ...205 13 21 Installing the right fuel tank spoiler F02062 10 Main work Position the right fuel tank spoiler with holding lug 1 on bushing 2 and push backward laterally Press the right fuel tank spoiler...

Page 208: ...t Guideline Screw fuel tank spoiler M6 5 Nm 3 7 lbf ft The front edge of the right fuel tank spoiler is evenly aligned Tighten all the screws of the right fuel tank spoiler Guideline Remaining screws...

Page 209: ...SERVICE WORK ON THE CHASSIS 13 207 13 22 Removing the front fender F02050 10 Remove screws 1 Remove screws 2 Take the fender off to the front...

Page 210: ...rews 1 but do not tighten yet Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount screws 2 but do not tighten yet Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft The fender is evenly a...

Page 211: ...on the opposite side 13 25 Installing the fork protector F02051 11 Position the fork protector Mount screw 1 but do not tighten yet Guideline Screw fork protector M5x12 5 Nm 3 7 lbf ft Mount screws 2...

Page 212: ...Preparatory work Raise motorcycle with rear lifting gear p 176 Remove the front fender p 207 Lift the motorcycle with the front lifting gear p 177 F02053 10 Main work Push dust boots 1 of both fork l...

Page 213: ...e brake discs with brake cleaner when nec essary Clean and oil the dust boots and inner fork tubes of both fork legs Universal oil spray p 343 Press the dust boots back into the installation position...

Page 214: ...13 SERVICE WORK ON THE CHASSIS 212 13 27 Removing the windshield F02054 10 Remove screw 1 and windshield 2...

Page 215: ...ORK ON THE CHASSIS 13 213 13 28 Installing the windshield F02055 10 Position windshield 1 in upper recess A or in lower recess B Mount and tighten screw 2 Guideline Remaining screws chassis M5 5 Nm 3...

Page 216: ...13 SERVICE WORK ON THE CHASSIS 214 13 29 Removing left fuel tank cover F01937 10 Remove fitting 1 Remove screws 2 Remove screw 3 Remove left fuel tank cover...

Page 217: ...rew fuel tank cover M6x12 8 Nm 5 9 lbf ft Mount screws 2 but do not tighten yet Guideline Screw fuel tank cover M6x18 5 Nm 3 7 lbf ft Loctite 243 Mount fitting 3 but do not tighten yet Guideline Screw...

Page 218: ...13 SERVICE WORK ON THE CHASSIS 216 Guideline Screw fuel tank cover M6x12 8 Nm 5 9 lbf ft Screw fuel tank cover M6x18 5 Nm 3 7 lbf ft Loctite 243 Screw fuel tank cover M6 5 Nm 3 7 lbf ft Loctite 243...

Page 219: ...SERVICE WORK ON THE CHASSIS 13 217 13 31 Removing right fuel tank cover F01939 10 Pull out tube 1 from the angle piece Remove fitting 2 Remove screws 3 Remove screw 4 Remove right fuel tank cover...

Page 220: ...rew fuel tank cover M6x12 8 Nm 5 9 lbf ft Mount screws 2 but do not tighten yet Guideline Screw fuel tank cover M6x18 5 Nm 3 7 lbf ft Loctite 243 Mount fitting 3 but do not tighten yet Guideline Screw...

Page 221: ...el tank cover M6x12 8 Nm 5 9 lbf ft Screw fuel tank cover M6x18 5 Nm 3 7 lbf ft Loctite 243 Screw fuel tank cover M6 5 Nm 3 7 lbf ft Loctite 243 Attach tube 4 to the angle piece 13 33 Removing engine...

Page 222: ...13 SERVICE WORK ON THE CHASSIS 220 F01929 10 Remove screws 2 F01930 10 Remove screws 3...

Page 223: ...IS 13 221 F02063 10 Remove screws 4 and engine guard 5 13 34 Installing the engine guard F02063 11 Position engine guard 1 Mount screws 2 but do not tighten yet Guideline Screw engine guard M6x10 10 N...

Page 224: ...11 Mount screws 4 but do not tighten yet Guideline Screw fuel tank cover M6x12 8 Nm 5 9 lbf ft The engine guard is directed evenly toward the front Tighten all the screws of the engine guard Guidelin...

Page 225: ...SERVICE WORK ON THE CHASSIS 13 223 F01928 11 Attach tube 5 to the angle piece...

Page 226: ...e impair the function of the ABS Only allow the rear wheel to spin with the front brake applied away from public road traffic if the ABS is switched off Do not make any changes to the suspension trave...

Page 227: ...er of accidents Driving aids can only prevent a rollover within the physical limitations It is not always possible to compensate for extreme riding situations for example with luggage loaded with a hi...

Page 228: ...witched on and go out after starting off If it does not go out after starting off or if it lights up while riding this indicates a fault in the ABS system In this case the ABS is no longer enabled and...

Page 229: ...98 10 Check front and rear brake disc thickness at multiple points for the dimension A Info Wear will reduce the thickness of the brake disc at con tact surface 1 of the brake linings Brake discs wear...

Page 230: ...uid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake system and do not continue riding until the problem is...

Page 231: ...ront brake fluid p 229 14 4 Adding the front brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the spec...

Page 232: ...Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accide...

Page 233: ...brake fluid from a sealed container Preparatory work Check the front brake linings p 232 F02065 10 Main work Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove scr...

Page 234: ...not changed in time the brake lining carriers grind against the brake disc As a consequence the braking effect is greatly reduced and the brake discs are destroyed Check the brake linings regularly F0...

Page 235: ...n the rear brake Set the free travel on the foot brake lever in accordance with the specification F02000 10 Detach spring 1 Move the foot brake lever back and forth between the end stop and the contac...

Page 236: ...d do not continue riding until the problem is eliminated Your authorized KTM workshop will be glad to help Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake f...

Page 237: ...be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid...

Page 238: ...ubstances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It...

Page 239: ...1 p 339 Mount and tighten screw cap 1 with the insert and mem brane 2 Info Immediately clean up any brake fluid that has over flowed or spilled with water 14 9 Checking the rear brake linings Warning...

Page 240: ...ence the braking effect is greatly reduced and the brake discs are destroyed Check the brake linings regularly F02096 10 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 04 i...

Page 241: ...WHEELS TIRES 15 239 15 1 Removing the front wheel Preparatory work Raise motorcycle with rear lifting gear p 176 Remove the front fender p 207 Lift the motorcycle with the front lifting gear p 177...

Page 242: ...ove screws 3 and 4 Press back the brake linings by slightly tilting the left and right brake caliper laterally on the brake disc Pull the left and right brake caliper carefully back from the brake dis...

Page 243: ...eel spindle out of the axle clamp Remove screw 5 Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake discs are not damaged...

Page 244: ...effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary F01964 11 Check the wheel bearing for damage and wear If the wheel bearing is damaged...

Page 245: ...pacer 2 on the right in the direction of travel Insert wide spacer 3 on the left in the direction of travel Info Arrow B indicates the direction of travel of the front wheel The ABS sensor wheel is on...

Page 246: ...e wheel spindle Grease wheel spindle lightly Long life grease p 342 Jack up the front wheel into the fork position it and insert the wheel spindle Mount and tighten screw 4 Guideline Screw front wheel...

Page 247: ...ngs are in contact with the brake disc and there is a pressure point Secure the hand brake lever in the activated position The brake calipers straighten Tighten screws 5 on both sides Guideline Screw...

Page 248: ...g gear p 176 F02067 11 Operate the front brake and compress the fork a few times firmly The fork legs straighten Tighten screws 8 Guideline Screw fork stub M8 15 Nm 11 1 lbf ft 15 3 Removing the rear...

Page 249: ...the brake caliper toward the brake disc to push back the brake piston Remove screw 1 and pull wheel speed sensor 2 out of the hole Remove nut 3 Take off chain adjuster 4 Only pull out wheel spindle 5...

Page 250: ...the rear wheel and remove the wheel spindle Pull the rear wheel back until the brake caliper bracket is sus pended freely between the brake disc and rim Warning Danger of accidents Damaged brake discs...

Page 251: ...braking effect to start with at the rear brake after installing the rear wheel Actuate the foot brake several times before going on a ride until you can feel a firm pressure point Main work Check the...

Page 252: ...RES 250 Clean and grease the thread of the wheel spindle and nut Long life grease p 342 Clean and grease the wheel spindle Long life grease p 342 Clean the contact areas on the brake caliper bracket a...

Page 253: ...ten it yet Info Mount the left and right chain adjusters in the same position Make sure that chain adjusters 2 are fitted correctly on the adjusting screws Tighten nut 3 Guideline In order for the rea...

Page 254: ...the rear of the motorcycle from the lifting gear p 176 15 5 Checking the rear hub damping rubber pieces Info The engine power is transmitted from the rear sprocket to the rear wheel via the 6 damping...

Page 255: ...all the damping rubber pieces of the rear hub F02074 10 Lay the rear wheel on a workbench with the rear sprocket fac ing upwards and insert the wheel spindle in the hub To check play A hold the rear w...

Page 256: ...r authorized KTM workshop will be glad to help Warning Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling charac teristic Different tire tread patterns ca...

Page 257: ...the braking and handling characteristics of the vehi cle Worn tires have a negative effect on handling characteristics especially on wet surfaces 400602 10 Check the front and rear tires for cuts embe...

Page 258: ...eek of manufacture and the last two digits the year of manu facture KTM recommends that the tires be changed after 5 years at the latest regardless of the actual state of wear If the tires are more th...

Page 259: ...e pressure solo with passenger front 2 4 bar 35 psi rear 2 4 bar 35 psi Offroad tire pressure front 1 8 bar 26 psi rear 1 8 bar 26 psi Tire pressure full payload front 2 6 bar 38 psi rear 2 9 bar 42 p...

Page 260: ...orm in the wheel Other spokes will become looser as a result Check spoke tension regularly and in particular on a new vehicle Your authorized KTM workshop will be glad to help 400694 01 Strike each sp...

Page 261: ...a faulty tube This greatly reduces the risk of a sudden loss in pressure The masses and moments of inertia of these wheels are smaller than in conventional spoke wheels with a tube This results in be...

Page 262: ...ire repair spray After repairing a tire with tire repair spray ride slowly and carefully Ride no further than to the nearest workshop and have the tire changed Tire repair spray should only be used in...

Page 263: ...fog snow or rain Ensure that the appropriate type of lighting is always selected If necessary switch off the daytime running lights using the menu before going on a ride or when stopped so that the l...

Page 264: ...acid and battery gases cause serious chemical burns Keep 12 V batteries out of the reach of children Wear suitable protective clothing and safety glasses Avoid contact with battery acid and battery g...

Page 265: ...ices will be damaged if the 12 V battery is dis charged or missing Never operate the vehicle with a discharged 12 V battery or without a 12 V battery Preparatory work Switch off the ignition by turnin...

Page 266: ...CTRICAL SYSTEM 264 F02075 10 Main work Pull the diagnostic connector 1 out of the bracket and hang to the side Remove screw 2 Raise the battery mounting element 3 at the rear and remove in upward dire...

Page 267: ...16 265 F02076 10 Disconnect negative cable 4 from the 12 V battery Remove positive terminal cover 5 Disconnect positive cable 6 from the 12 V battery Pull the 12 V battery upwards and out of the batt...

Page 268: ...away from the 12 V battery Only charge 12 V batteries in well ventilated rooms Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes with water for...

Page 269: ...HTZ12A BS p 326 The battery terminals face opposite the direction of travel Connect positive cable 1 to the 12 V battery Guideline Screw battery termi nal M6 4 5 Nm 3 32 lbf ft Mount positive termina...

Page 270: ...ight in the holding lugs and push downward at the back Mount and tighten screw 5 Guideline Screw battery sup port bracket M6 4 5 Nm 3 32 lbf ft Position the diagnostics connector 6 in the holder Finis...

Page 271: ...d area immediately with plenty of water in the event of contact with the skin Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and battery gases get into...

Page 272: ...electrolyte escapes through the safety valves This reduces the capacity of the 12 V battery If the 12 V battery is depleted from starting the vehicle repeatedly the battery must be charged immedi ate...

Page 273: ...he battery charger Battery charger 58429074000 In addition this battery charger can be used to test the open circuit voltage the starting ability of the 12 V battery and the alternator In addition you...

Page 274: ...charge the 12 V battery regularly when the motorcy cle is not being used 3 months F02079 10 Mount positive terminal cover 2 Connect negative cable 1 to the 12 V battery Guideline Screw battery termi n...

Page 275: ...he electrical system Only use fuses with the required ampere value Do not bypass or repair fuses Info The main fuse protects all power consumers of the vehicle The main fuse is under the seat Preparat...

Page 276: ...p 1 F02081 10 Remove faulty main fuse 2 Info A faulty fuse has a burned out fuse wire A A spare fuse 3 is located in the starter relay Insert a new main fuse Fuse 58011109130 p 326 Tip Insert a new sp...

Page 277: ...otection cap 1 Finishing work Mount the seat p 180 Set the time and date 16 6 Changing the ABS fuses Warning Fire hazard Incorrect fuses overload the electrical system Only use fuses with the required...

Page 278: ...se box Preparatory work Switch off the ignition by turning the ignition key to the posi tion Remove the seat p 179 F02082 10 To change the fuse of the ABS hydraulic unit Remove the protection cap and...

Page 279: ...e with the correct rating Fuse 75011088025 p 326 Tip Insert spare fuse 4 in the fuse box so that it is available if needed Mount the protection cap Finishing work Mount the seat p 180 16 7 Changing th...

Page 280: ...use box containing the fuses of individual power consumers is located under the seat Preparatory work Switch off the ignition by turning the ignition key to the posi tion Remove the seat p 179 F02083...

Page 281: ...10 A fuel pump Fuse 4 10 A radiator fan Fuse 5 10 A horn combination instrument brake light Fuse 6 10 A high beam low beam position light tail light license plate lamp Fuse 7 10 A ACC1 Fuse 8 10 A AC...

Page 282: ...seat p 180 16 8 Checking the headlight setting 400726 10 Park the vehicle on a horizontal surface in front of a light colored wall and make a mark at the height of the center of the low beam headligh...

Page 283: ...undary must be exactly on the lower mark ing when the motorcycle is ready to be operated with the rider mounted along with any luggage and a passenger if applicable If the boundary between light and d...

Page 284: ...Remove the left mask spoiler F02086 10 Turn adjusting screw 2 to adjust the headlight range Info Turn clockwise to reduce the headlight range turn counterclockwise to increase the headlight range If y...

Page 285: ...dark boundary must lie exactly on lower mark ing B when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applicable F02085 10 Position left mask spo...

Page 286: ...ctor 1 is located under the battery cover 16 11 Front ACC1 and ACC2 F02097 10 Installation location The front power supplies ACC1 1 and ACC2 2 are located behind the headlight Info The front power sup...

Page 287: ...ELECTRICAL SYSTEM 16 285 16 12 ACC1 and ACC2 rear F02087 10 Installation location Power supplies ACC1 1 and ACC2 2 rear are located under the seat...

Page 288: ...o flow into compensating tank 3 When the tem perature falls this surplus coolant is sucked back into the cooling system This ensures that operating the vehicle at the specified coolant temperature wil...

Page 289: ...In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allo...

Page 290: ...ct the coolant level in the compensating tank p 288 17 3 Correcting the coolant level in the compensating tank Warning Danger of scalding During motorcycle operation the coolant gets very hot and is u...

Page 291: ...s swallowed Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the ey...

Page 292: ...17 COOLING SYSTEM 290 F02088 10 Add coolant until the coolant reaches the specified level Guideline The coolant level must be between MIN and MAX Coolant p 339 Mount the cover of the compensating tank...

Page 293: ...ridability the motorcycle traction control allows high slip on the rear wheel The Anti Wheelie mode is deactivated RALLY Setting with homologated performance and extremely direct response The motorcyc...

Page 294: ...may spin during strong acceleration and on surfaces with low grip resulting in a risk of falling After the ignition is switched on motorcycle traction con trol is enabled again In the combination inst...

Page 295: ...the minimum The slip adjustment can be set while riding with a closed menu using the UP or DOWN button Info The slip adjustment is only available in drive mode RALLY 18 4 Throttle Response F01803 01 P...

Page 296: ...18 TUNING THE ENGINE 294 Info Throttle response is only available in drive mode RALLY...

Page 297: ...motorcycle upright on a horizontal surface Check the engine oil level Info After switching off the engine wait one minute before checking the level The engine oil must be between marking A and mark i...

Page 298: ...lothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils gre...

Page 299: ...1066 10 Main work Rest the motorcycle on its side stand on a horizontal surface Place an appropriate container under the engine Remove filler plug 1 with the O ring F01974 10 Remove oil drain plugs 2...

Page 300: ...ter housing Lock ring plier 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing surfaces F01976 10 Insert new oil filter 5 Info Only insert the oil filter by hand Oil th...

Page 301: ...A and oil screens B of the oil drain plugs F01974 10 Mount the oil drain plugs 2 with magnets and new seal rings and tighten Guideline Plug oil screen M20x1 5 20 Nm 14 8 lbf ft Fill up with engine oi...

Page 302: ...ways make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Start the engine and check that it is o...

Page 303: ...ils We recommend changing the engine oil when neces sary Mount and tighten filler plug 1 with the O ring Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconscious...

Page 304: ...cation F02090 10 Check the clutch lever for smooth operation Move the handlebar to the straight ahead position Pull the clutch lever until resistance is perceptible and deter mine the free travel A Fr...

Page 305: ...tting the free travel of the clutch lever F02091 10 Move the handlebar to the straight ahead position Loosen lock nut 1 Adjust the free travel A by turning adjusting screw 2 Guideline Free travel A of...

Page 306: ...jet directly on to electrical components connectors throttle cables or bearings Maintain a minimum distance between the nozzle of the pressure cleaner and the component Minimum clearance 60 cm 23 6 i...

Page 307: ...r and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the vehicle with water first If the vehicle was operated in road salt clean it with cold water Warm water would enhance...

Page 308: ...pivot points Clean the chain p 181 Treat bare metal except for brake discs and the exhaust sys tem with a corrosion inhibitor Preserving materials for paints metal and rubber p 343 Treat the painted...

Page 309: ...ld therefore take precau tions against aggressive road salt After riding on salted roads thoroughly clean the vehicle with cold water and dry it well Warm water enhances the corrosive effects of salt...

Page 310: ...k and all other bare or zinc plated parts except the brake discs with a wax based corrosion inhibitor Info Corrosion inhibitor must not come in contact with the brake discs as this would greatly reduc...

Page 311: ...n this way you can avoid long workshop waiting times at the start of the new season 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additi...

Page 312: ...unning 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 the exhaust system to rust 21 2 Preparing fo...

Page 313: ...esent Check the ground connection The engine only turns if the clutch lever is drawn The vehicle is in gear Shift the transmission into neutral The vehicle is in gear and the side stand is folded out...

Page 314: ...l injection Read out the fault memory using the KTM diagnostics tool Engine overheats Too little coolant in cooling sys tem Check the cooling system for leaks Check the coolant level in the compen sat...

Page 315: ...p lights up The ABS fuse is blown Change the ABS fuses p 275 Wheel speeds of front and rear wheels differ greatly Stop switch off the ignition start again Malfunction in ABS Read out the ABS fault mem...

Page 316: ...consumers p 277 12 V battery discharged Ignition was not switched off when vehicle was parked Charge the 12 V battery p 269 The 12 V battery is not being charged by the alternator Check the charging v...

Page 317: ...ve diameter intake 36 mm 1 42 in Valve diameter exhaust 29 mm 1 14 in Valve play cold Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Exhaust at 20 C 68 F 0 15 0 20 mm 0 0059 0 0079 in Crankshaft be...

Page 318: ...Fourth gear 22 28 Fifth gear 24 26 Sixth gear 23 22 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator...

Page 319: ...nt M5 2 Nm 1 5 lbf ft Loctite 243 Oil nozzle for piston cooling M5 2 Nm 1 5 lbf ft Loctite 243 Oil nozzle in cylinder head M5 2 Nm 1 5 lbf ft Loctite 243 Remaining screws engine M5 6 Nm 4 4 lbf ft Scr...

Page 320: ...4 lbf ft Screw bearing bridge of balancer shaft bearing M6 12 Nm 8 9 lbf ft Screw camshaft bearing bridge M6 10 Nm 7 4 lbf ft Screw clutch cable retaining bracket M6 10 Nm 7 4 lbf ft Screw clutch cov...

Page 321: ...pump unit M6 10 Nm 7 4 lbf ft Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 Screw shift shaft retaining bracket M6 10 Nm 7 4 lbf ft Loct...

Page 322: ...screws for engine M8 20 Nm 14 8 lbf ft Screw plug locking screw M8 15 Nm 11 1 lbf ft Screw conrod bearing M8 1st stage 5 Nm 3 7 lbf ft 2nd stage 15 Nm 11 1 lbf ft 3rd stage 90 Collar and thread oiled...

Page 323: ...Loctite 243 Spark plug M10 10 Nm 7 4 lbf ft Oil pressure sensor M10x1 10 Nm 7 4 lbf ft Screw plug bearing support M10x1 12 Nm 8 9 lbf ft Loctite 243 Screw plug cam lever axis M10x1 10 Nm 7 4 lbf ft Sc...

Page 324: ...g cylinder head oil drain M12x1 5 15 Nm 11 1 lbf ft Screw rotor M12x1 5 90 Nm 66 4 lbf ft Loctite 243 Screw plug water jacket M16x1 5 20 Nm 14 8 lbf ft Nut engine sprocket M20x1 5 100 Nm 73 8 lbf ft L...

Page 325: ...Capacities 23 3 1 Engine oil Engine oil 2 8 l 3 qt Engine oil SAE 10W 50 p 340 23 3 2 Coolant Coolant 1 60 l 1 69 qt Coolant p 339 23 3 3 Fuel A00420 10 Please observe the labels on EU fuel pumps Fue...

Page 326: ...PLOR 5548 Shock absorber WP SuspensionXPLOR 5746 Suspension travel front 240 mm 9 45 in rear 240 mm 9 45 in Brake system front Double disc brake with radially mounted four piston brake calipers floati...

Page 327: ...38 psi rear 2 9 bar 42 psi Secondary drive ratio 16 45 Chain 5 8 x 1 4 520 X ring Steering head angle 63 7 Wheelbase 1 528 mm 60 16 in Seat height unloaded 880 mm 34 65 in Ground clearance unloaded 26...

Page 328: ...apacity 10 Ah Maintenance free Fuse 75011088010 10 A Fuse 75011088015 15 A Fuse 75011088025 25 A Fuse 58011109130 30 A Low beam high beam LED Daytime running light position light LED Combination instr...

Page 329: ...e possible series production tires Additional information is available in the Service section under http www ktm com 23 7 Fork Fork article number 14 18 8S 54 Fork WP SuspensionXPLOR 5548 Compression...

Page 330: ...85 kg 165 187 lb 6 7 N mm 38 3 lb in Fork length 912 mm 35 91 in Fork oil per fork leg 630 5 ml 21 3 0 17 fl oz Fork oil SAE 4 48601166S1 p 341 23 8 Shock absorber Shock absorber article number 01 18...

Page 331: ...port 12 clicks Full payload 9 clicks Spring preload Preload Adjuster Comfort 4 turns Standard 4 turns Sport 4 turns Full payload 10 turns Fitted length 380 mm 14 96 in Spring length 210 mm 8 27 in Spr...

Page 332: ...ing screws chassis M4 3 Nm 2 2 lbf ft Screw fixed grip left M4 2 Nm 1 5 lbf ft Remaining nuts chassis M5 5 Nm 3 7 lbf ft Remaining screws chassis M5 5 Nm 3 7 lbf ft Screw for throttle grip M5 3 5 Nm 2...

Page 333: ...e 243 Screw trim M5 3 Nm 2 2 lbf ft Nut hand brake lever M6 Attach torque to nut 10 Nm 7 4 lbf ft Nut push rod foot brake lever M6 6 Nm 4 4 lbf ft Nut shift rod M6 6 Nm 4 4 lbf ft Nut shift rod M6LH 6...

Page 334: ...ft Loctite 243 Screw foot brake cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw footrest bracket rear M6 6 Nm 4 4 lbf ft Loctite 243 Screw front brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw front...

Page 335: ...1 5 lbf ft Loctite 243 Screw manifold clamp M6 8 Nm 5 9 lbf ft Copper paste Screw rear brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw rear wheel speed sensor M6 6 Nm 4 4 lbf ft Screw seat fixing M6...

Page 336: ...m 8 9 lbf ft Screw engine fixing arm linkage bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw engine guard frame M8 25 Nm 18 4 lbf ft Loctite 243 Screw fork stub M8 15 Nm 11 1 lbf ft Screw grab handle M...

Page 337: ...8 lbf ft Loctite 243 Screw top triple clamp M8 15 Nm 11 1 lbf ft Securing bolt for brake linings M8 10 Nm 7 4 lbf ft Remaining nuts chassis M10 45 Nm 33 2 lbf ft Remaining screws chassis M10 45 Nm 33...

Page 338: ...k absorber M12 80 Nm 59 lbf ft Loctite 2701 Screw swingarm pivot M12 100 Nm 73 8 lbf ft Screw top shock absorber M12 80 Nm 59 lbf ft Loctite 2701 Lambda sensor M18x1 5 50 Nm 36 9 lbf ft Adjusting scre...

Page 339: ...owing Internet address Certification website http www ktm com 252m1100 KTM AG hereby declares that the Immo641 wireless system conforms with the relevant guidelines The full text of the Declaration of...

Page 340: ...24 DECLARATIONS OF CONFORMITY 338 24 2 Country specific declarations of conformity V01514 01...

Page 341: ...1 Coolant Guideline Only use high grade silicate free coolant with corrosion inhibitor additive for aluminum motors Low grade and unsuitable antifreeze causes corrosion deposits and frothing Do not us...

Page 342: ...for antifreeze protection dilution and miscibility compatibility with other coolants Recommended supplier MOTOREX COOLANT M3 0 Engine oil SAE 10W 50 Standard classification JASO T903 MA2 p 344 SAE p 3...

Page 343: ...2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 Standard cla...

Page 344: ...Clean Fuel additive Recommended supplier MOTOREX Fuel Stabilizer Long life grease Recommended supplier MOTOREX Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX Moto Clean Perfect fini...

Page 345: ...er MOTOREX Moto Protect Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Street chain spray Guideline Recommended supplier MOTO...

Page 346: ...ce intervals are demanded for automobile engines the focus for motorcycle engines is on high performance at high engine speeds In most motorcycle engines the transmission and clutch are lubricated wit...

Page 347: ...for wireless communication with appropriate cellphones and headsets for telephony and audio MTC Motorcycle Traction Control Auxiliary function of the motor control that reduces engine torque with spi...

Page 348: ...29 LIST OF ABBREVIATIONS 346 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 349: ...vehicle electronics Come safely to a halt and contact an authorized KTM workshop ABS warning lamp lights up flashes yellow Status or error messages relating to ABS The ABS warning lamp flashes if the...

Page 350: ...usly with the turn signal The turn signal is switched on The idle indicator lamp lights up green The transmission is in neutral The cruise control system indicator lamp optional lights up green The cr...

Page 351: ...iary substances 18 B Battery cover installing 196 removing 195 Brake discs checking 227 Brake fluid of rear brake adding 235 of the front brake adding 229 Brake fluid level of front brake checking 228...

Page 352: ...Theme 110 Distance 118 DRL 116 Extra Functions 122 Favorites 106 Favorites display 76 fuel level display 74 Fuel Cons 119 General Info 93 Headset 88 ice warning 58 indicator lamps 60 KTM MY RIDE 78 L...

Page 353: ...ch 32 overview 33 Coolant level checking in the compensating tank 287 correcting in the compensating tank 288 Cooling system 286 Cruise control system operation 34 Customer service 19 D Declarations o...

Page 354: ...oots cleaning 210 Fork part number 29 Fork protector installing 209 removing 209 Free travel of clutch lever adjusting 303 checking 302 Front fender installing 208 removing 207 Front wheel installing...

Page 355: ...Luggage 139 Luggage rack plate 50 M Main fuse changing 273 Manufacturer warranty 18 Misuse 12 Motorcycle cleaning 304 lifting with front lifting gear 177 rear from the lifting gear removing 176 rear l...

Page 356: ...ng 217 Right fuel tank spoiler installing 205 removing 202 Right side cover installing 194 removing 193 S Safe operation 14 Seat mounting 180 removing 179 Seat lock 51 Service 19 Service schedule 161...

Page 357: ...mpartment on the left closing 46 opening 45 Storage compartment on the right closing 48 opening 47 Switch on the left side of the handlebar 32 on the right side of the handlebar 39 T Technical data ca...

Page 358: ...tire system 259 Turn signal switch 37 Type label 27 U Use definition 12 V Vehicle identification number 26 View of vehicle front left 22 rear right 24 W Windshield adjusting 126 installing 213 removi...

Page 359: ...3213919en 3213919en 02 2019 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KISKA KTM...

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