KTM 890 DUKE 2021 Owner'S Manual Download

Page: 114 / 143

19 SERVICE WORK ON THE ENGINE

112

19.4

Checking the free travel of the clutch lever

Note

Clutch damage

If there is no free travel by the clutch lever, the clutch will begin to slip.

–

Check the free travel of the clutch lever each time before using the motorcycle.

–

Adjust the free travel of the clutch lever when necessary in accordance with the specification.

V01187-12

–

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

Free travel of clutch
lever

5 mm (0.2 in)

» If the free travel of the clutch lever does not meet specifi-

cations:

–

Set the free travel of the clutch lever.

(

p. 112)

–

Move the handlebar to and fro over the entire steering range.

The free travel of the clutch lever must not change.

» If the free travel of the clutch lever changes:

–

Check the routing of the clutch cable.

19.5

Setting the free travel of the clutch lever

V01234-10

–

Move the handlebar to the straight-ahead position.

–

Loosen lock nut

–

Adjust the free travel

by turning adjusting screw

Guideline

Free travel of clutch
lever

5 mm (0.2 in)

–

Tighten lock nut

Summary of Contents for 890 DUKE 2021

Page 1: ...OWNER S MANUAL 2021 890 DUKE Art no 3214300en...

Page 2: ......

Page 3: ...rials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop produc tion of a particular model without prior notice KT...

Page 4: ...4 5 Turn signal switch 17 6 4 6 Horn button 17 6 5 Switches on the right side of the handlebar 17 6 5 1 Start button emergency OFF switch 17 6 6 Ignition and steering lock 18 6 7 Opening fuel tank fi...

Page 5: ...1 Adjusting the spring preload of the shock absorber 63 13 SERVICE WORK ON THE CHASSIS 64 13 1 Raising the motorcycle with the rear lifting gear 64 13 2 Removing the rear of the motorcycle from the l...

Page 6: ...ERVICE WORK ON THE ENGINE 109 19 1 Checking the engine oil level 109 19 2 Changing the engine oil and oil filter cleaning the oil screens 109 19 3 Adding engine oil 111 19 4 Checking the free travel o...

Page 7: ...ned experts using the auxiliary tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a t...

Page 8: ...afely Therefore read this instruction and all further instructions included carefully The safety instructions are highlighted in the text and are referred to at the relevant passages Info Various info...

Page 9: ...nger Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others Do not operate the vehicle if you are not fit to ride due to alcohol drugs or medication Do not oper...

Page 10: ...your motorcycle responsibly you can ensure that problems and conflicts do not occur To protect the future of the motorcycle sport make sure that you use your motorcycle legally display environmental...

Page 11: ...erequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly carried out as described in the Owner s Manual An incor...

Page 12: ...CLE 10 4 1 View of vehicle front left example A00920 10 1 Combination instrument p 22 2 Ignition and steering lock p 18 3 Clutch lever p 14 4 Seat lock p 19 5 Side stand p 21 6 Shift lever p 20 7 Engi...

Page 13: ...r right example A00921 10 1 Tool set p 19 2 Fuel tank filler cap 3 Light switch p 15 3 Turn signal switch p 17 3 Horn button p 17 4 Start button emergency OFF switch p 17 5 Hand brake lever p 14 6 Lev...

Page 14: ...1 is located on the steering head on the left The type label Australia 2 is located on the frame behind the steering head at the top left 5 3 Key number V01200 10 The key number 1 can be found on the...

Page 15: ...on the inner side of the fork stub 5 6 Shock absorber article number V01201 10 Shock absorber article number 1 is on the left side of the shock absorber 5 7 Steering damper article number H02669 10 S...

Page 16: ...ake is engaged using the hand brake lever 6 3 Throttle grip V01189 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...

Page 17: ...ES The last saved speed is reapplied Every subsequent brief pressing increases the target speed by 1 km h or 1 mph Press and hold the cruise control system tip switch in posi tion RES The target speed...

Page 18: ...or snow where there is poor visibility or on 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 19: ...side of the handlebar Possible states The horn button is in the basic position The horn button is pressed The horn is operated in this position 6 5 Switches on the right side of the handlebar 6 5 1 St...

Page 20: ...of the vehicle If any fuel is spilled 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 co...

Page 21: ...ghly flammable toxic and a health hazard Check that the fuel tank filler cap is locked cor rectly after closing Change your clothing if fuel spills on them Rinse the affected area immediately with ple...

Page 22: ...99 01 The passenger foot pegs can be folded up and down Possible states Passenger foot pegs folded up For operation without a pas senger Passenger foot pegs folded down For operation with a pas senger...

Page 23: ...le 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 with the safety starting system follow the riding instruction...

Page 24: ...function check Info The malfunction indicator lamp always lights up as long as the engine is not running If the engine is running and the malfunction indicator lamp lights up stop taking care not to...

Page 25: ...sensor The display mode cannot be changed manually 7 4 Warnings H02619 01 If the general warning lamp lights up among the indicator lamps p 23 the corresponding message appears in the display Pressin...

Page 26: ...llow The OBD has detected a malfunction in the vehicle electronics Come safely to a halt and contact an authorized KTM workshop ABS warning lamp lights up yellow Status or error messages relating to A...

Page 27: ...ip optional p 26 3 Cruise control indicator optional p 27 4 Bluetooth optional 5 Ride Mode p 107 6 Unit of speedometer 7 Fuel level display p 27 8 Coolant temperature indicator p 27 9 Fuel range displ...

Page 28: ...nu is opened the speed is still displayed 1 Throttle response optional p 108 2 Slip adjustment optional p 108 3 Launch Control optional p 52 4 Anti Wheelie Mode 7 8 Heated grip optional F02756 10 When...

Page 29: ...mergency OFF switch is switched on the fuel level display is next updated after 2 minutes The fuel level display flashes if the combination instrument does not receive a signal from the fuel level sen...

Page 30: ...the Clock Date menu Info The time must be reset if the 12 V battery was discon nected from the vehicle or the fuse was removed 7 14 ABS display F02751 10 The ABS mode setting is shown in the 1 area o...

Page 31: ...9 01 Press the SET button when the menu is closed Press the UP or DOWN button until the Trips Data menu is marked on the display Press the SET button to open the menu Press the UP or DOWN button until...

Page 32: ...from Fuel range are deleted 7 16 4 General Info V01111 01 Warning Danger of accidents The tire pressure monitoring sys tem does not eliminate the necessity to check the tires before going on a ride To...

Page 33: ...n the menu Press the UP or DOWN button until Bluetooth is marked on the display Switch the Bluetooth on and off using the SET button Info The Bluetooth function can only be used in conjunction with KT...

Page 34: ...he display Press the SET button to open the menu Press the UP or DOWN button until the Settings menu is marked on the display Press the SET button to open the menu Press the UP or DOWN button until Un...

Page 35: ...marked on the display Press the SET button to open the menu Press the UP or DOWN button until the Settings menu is marked on the display Press the SET button to open the menu Press the UP or DOWN butt...

Page 36: ...DOWN button until DRL is marked on the dis play Press the SET button to switch the daytime running light on or off 7 16 14 TPMS warning V01141 01 Condition The motorcycle is stationary Model with TPM...

Page 37: ...y pressing the UP button Info In drive mode TRACK optional the UP button can be used to set the slip adjustment 7 16 16 Quick Selector 2 V01122 01 Condition The motorcycle is stationary Press the SET...

Page 38: ...utton until the Trips Data menu is marked on the display Press the SET button to open the menu Press the UP or DOWN button until the Settings menu is marked on the display Press the SET button to open...

Page 39: ...n the display Press the SET button to open the menu Use the UP or DOWN button to navigate through the warnings In the Warnings menu warnings that occurred are displayed and stored until they are no lo...

Page 40: ...hrottle when doing so 7 16 24 Anti wheelie mode optional V01142 01 Condition The TRACK riding mode optional is activated Press the SET button when the menu is closed Press the UP or DOWN button until...

Page 41: ...on to open the menu Press the UP or DOWN button until MTC is marked on the dis play Keep the SET button pressed for 3 5 seconds to switch MTC on or off Info Do not open the throttle when switching on...

Page 42: ...he motorcycle is stationary Press the SET button when the menu is closed Press the UP or DOWN button until the Motorcycle menu is marked on the display Press the SET button to open the menu Press the...

Page 43: ...Bluetooth visibility must be activated on the device that is to be paired Press the SET button when the menu is closed Press the UP or DOWN button until the KTM MY RIDE menu is marked on the display...

Page 44: ...ted Bluetooth optional is switched on Similarly the Bluetooth is also switched on when devices are paired Headset connected to a suitable audio device Press the SET button when the menu is closed Pres...

Page 45: ...hen devices are paired Headset linked with appropriate cellphone Warning Danger of accidents Headphone volume which is too high distracts attention from traffic activity Always select headphone volume...

Page 46: ...handlebar may break as a result Change the handlebar if the handlebar is damaged or bent V01210 10 Remove screws 1 Take off the handlebar clamps 2 Posi tion the handlebar so that screws 3 are accessib...

Page 47: ...1 Push the hand brake lever forward Adjust the basic position of the hand brake lever to your hand size by turning adjusting screw 1 Info Turn the adjusting screw clockwise to increase the distance be...

Page 48: ...the free travel A is present If necessary adjust the basic posi tion of the foot brake lever Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Hold screw 5 and tighten nut 4 Guideline Remai...

Page 49: ...usting the basic position of the shift lever H02668 10 Loosen nut 1 holding threaded rod 2 Loosen nut 3 holding threaded rod 2 Info Nut 3 has a left handed thread Turn threaded rod 2 to adjust the shi...

Page 50: ...els approved by KTM with the corresponding speed index Warning Danger of accidents New tires have reduced road grip The contact surface on new tires is not yet roughened Run in new tires with moderate...

Page 51: ...ording to the manufacturer s instructions Warning Danger of accidents Carrying luggage alters handling characteristics at high speed Adapt your speed to your payload Ride more slowly if your motorcycl...

Page 52: ...ge make sure you secure it firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels Do not exceed the maximum permissible weight a...

Page 53: ...motorcycle and check the rear mirror setting Check the fuel level 10 2 Starting the vehicle Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death...

Page 54: ...usly open the throttle carefully 10 4 Launch Control optional H02000 01 Launch Control is a vehicle electronics function Launch control adjusts the engine speed in order to achieve the best possible a...

Page 55: ...can shift up and down with out actuating the clutch Because there is no need to close the throttle grip uninterrupted gear shifts are possible The quickshifter uses the shifter shaft position to chec...

Page 56: ...rate speed until the tires reach operating tem perature Warning Danger of accidents New tires have reduced road grip The contact surface on new tires is not yet roughened Run in new tires with moderat...

Page 57: ...ward 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 o...

Page 58: ...enabled in the combination instrument you can shift down in the speed range shown with out pulling the clutch lever Info The maximum engine speed before shifting down in revolutions per minute is sho...

Page 59: ...emove salt from the brake linings and the brake discs Warning Danger of accidents ABS may increase the stopping distance in certain situations Adjust application of the brakes to the respective riding...

Page 60: ...ng the vehicle are designed only for the weight of the vehicle Park the vehicle on a firm and level surface Ensure that nobody sits on the vehicle when the vehicle is parked on a stand Note Fire hazar...

Page 61: ...or refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of po...

Page 62: ...not allow fuel to enter the groundwater the soil or the sewage system V01463 10 Switch off the engine Open fuel tank filler cap p 18 Fill the fuel tank with fuel up to the lower edge A of the filler...

Page 63: ...p 74 Check the brake lines for damage and leakage Check the front brake fluid level p 74 Check the rear brake fluid level p 77 Change the front brake fluid Change the rear brake fluid Check the free...

Page 64: ...000 km 620 mi Check the frame Check the link fork Check clean the oil nozzle for clutch lubrication Check the swingarm bearing for play Check the wheel bearing for play Change the coolant p 105 Empty...

Page 65: ...nfo The spring preload defines the initial status of the spring operation 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 l...

Page 66: ...parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 402029 10 Secure the motorcycle against falling over Remove the rear lifting gear and lean the vehicle on side st...

Page 67: ...downward Info The dust boots remove dust and coarse dirt particles from the inside fork tubes Over time dirt can accumu late behind the dust boots If this dirt is not removed the oil seals behind can...

Page 68: ...to the storage compartment lower the rear and push forward Press passenger seat downward until it clicks into place Warning Danger of accidents The seat can come loose from the anchoring if it is not...

Page 69: ...n the tank The holding lugs 2 engage in the loops B on the frame V01239 11 Mount and tighten screws 3 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finally check that the front rider s seat i...

Page 70: ...h the rear lifting gear p 64 400725 01 Main work Rinse off loose dirt with a soft jet of water Remove old grease residue with chain cleaner Chain cleaner p 132 After drying apply chain spray Street ch...

Page 71: ...ion does not meet the specification Adjust the chain tension p 69 Finishing work Remove the rear of the motorcycle from the lifting gear p 64 13 13 Adjusting the chain tension Warning Danger of accide...

Page 72: ...nt chain positions Tighten nuts 2 Make sure that chain adjusters 4 are fitted correctly on adjusting screws 3 Tighten nut 1 Guideline Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Thread and contac...

Page 73: ...0 71 in If distance B is greater than the specified measurement Change the drivetrain kit Info When a new chain is mounted the rear sprocket and engine sprocket should also be changed New chains wear...

Page 74: ...chain sliding guard If the chain sliding guard is highly worn on the underside in the marked area E Replace the chain sliding guard Check that the chain sliding guard is firmly seated If the chain sli...

Page 75: ...ing road surfaces steep descents or full braking without disengaging the gear Adapt your riding style to the road conditions and your driving ability The ABS operates with two independent brake circui...

Page 76: ...ront and rear brake discs for damage cracking and deformation If the brake disc exhibits damage cracking or deforma tion Change the front brake discs Change the rear brake disc 14 3 Checking the front...

Page 77: ...lothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately a...

Page 78: ...the braking effect If the brake linings are 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 de...

Page 79: ...nue 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 fluid for the f...

Page 80: ...is changed in accordance with the service schedule Your authorized KTM workshop will be glad to help Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease fi...

Page 81: ...ng effect If the brake linings are 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 C...

Page 82: ...iper has been removed Remove screws 4 Press back the brake linings by slightly tilting the right brake caliper laterally on the brake disc Pull the right brake caliper carefully back from the brake di...

Page 83: ...tact surfaces A of the spacers Long life grease p 132 V01246 10 Insert wide spacer 2 on the left in the direction of travel Insert narrow spacer 3 on the right in the direction of travel Info Arrow B...

Page 84: ...en screws 5 on both sides Guideline Screw front brake caliper M10x1 25 45 Nm 33 2 lbf ft Loctite 243 Position wheel speed sensor 6 in the hole Mount and tighten screw 7 Guideline Screw wheel speed sen...

Page 85: ...damage Hold 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...

Page 86: ...132 Clean the contact areas on the brake caliper bracket and link fork V01242 12 Engage the thrust bearing of brake caliper bracket B and the link fork Jack up the rear wheel into the link fork posit...

Page 87: ...ove the rear wheel p 82 V01252 10 Main work Check bearing 1 If the bearing is damaged or worn Change the bearing of the rear sprocket carrier Check the damping rubber pieces 2 of the rear hub for dam...

Page 88: ...handling character istic Only use tires wheels approved by KTM with the corresponding speed index Warning Danger of accidents New tires have reduced road grip The contact surface on new tires is not y...

Page 89: ...fe 400695 01 Remove the protection cap Check the tire pressure when the tires are cold Tire pressure when solo front 2 3 bar 33 psi rear 2 5 bar 36 psi Tire pressure with passenger full payload front...

Page 90: ...en down vehicle to the near est workshop instead of using tire repair spray Option With TPMS Note Material damage Tire repair spray damages the tire pressure sensor Note that after using tire repair s...

Page 91: ...are good Activate the daytime running light DRL in the combination instrument This is controlled by the ambient light sensor in the combination instrument When visibility conditions are good the low...

Page 92: ...d out of the battery compart ment 16 3 Installing the 12 V battery V01202 10 Main work Position the 12 V battery in the battery compartment 12 V battery HTZ12A BS p 124 The battery terminals face oppo...

Page 93: ...contain environmentally hazardous materials Do not dispose of 12 V batteries as household waste Dispose of 12 V batteries at a collection point for used batteries Note Environmental hazard Hazardous s...

Page 94: ...ty of the 12 V battery and to test the alternator In addition you cannot overcharge the 12 V battery with this device Info Charge the 12 V battery to a maximum of 10 of the capacity specified on the b...

Page 95: ...se is under the passen ger seat Preparatory work Remove the passenger seat p 66 V01205 10 Main work Remove protection cap 1 V01206 10 Remove faulty main fuse 2 Info A faulty fuse has a burned out fuse...

Page 96: ...01209 10 To change the fuse of the ABS hydraulic unit Remove the protection cap and fuse 1 Info A faulty fuse has a burned out fuse wire A Insert the spare fuse with the correct rating Fuse 7501108801...

Page 97: ...ty fuse Guideline Fuse 1 10 A ignition Fuse 2 10 A ignition engine control unit electronic fuel injection fuel vapor retention system lambda sensor immo bilizer alarm system Fuse 3 10 A fuel pump Fuse...

Page 98: ...t V01212 10 Completely unscrew adjusting screw 1 Info The adjusting screw is fastened to the headlight mask by a ball head holder Do not pull the adjusting screw out of the ball head adjuster V01217 1...

Page 99: ...sk rack must be removed in order to gain access to the ACC1 and ACC2 power supply Preparatory work Loosen the headlight mask with the headlight p 96 V01218 10 Main work Remove screws 1 Remove screws 2...

Page 100: ...tighten screws 2 Guideline Screw headlight EJOTPT K50x14 3 Nm 2 2 lbf ft Finishing work Mount the headlight mask with the headlight p 96 Check the headlight setting p 98 16 12 Checking the headlight s...

Page 101: ...ting screw 1 to adjust the headlight range Info Turn clockwise to increase the headlight range turn counterclockwise to reduce the headlight range If you have a payload you may have to correct the hea...

Page 102: ...n location Power supplies ACC1 1 and ACC2 2 front are located under the cover of the headlight mask rack 16 16 ACC1 and ACC2 rear V01215 10 Installation location The rear power supplies ACC1 1 and ACC...

Page 103: ...cle operation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other cooling system components if the engine or the cooling system are at operating temper...

Page 104: ...04 Mount cap 2 of the compensating tank Check the coolant level in the radiator The radiator must be filled completely If the coolant level does not match the specified value Check the coolant level a...

Page 105: ...st be between MIN and MAX If the coolant level in the compensating tank is not at the required level but the tank is not empty Remove cap of the compensating tank Replenish coolant up to a level betwe...

Page 106: ...he engine Remove screw 1 with the seal ring Remove the radiator cap Completely drain the coolant Mount and tighten screw 1 with a new seal ring Guideline Screw plug water pump drain hole EJOTALtracs P...

Page 107: ...sary add coolant Check coolant level in the compensating tank p 102 17 6 Changing the coolant Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do...

Page 108: ...ghten bleeder screw 3 immedi ately Coolant 1 6 l 1 7 qt Coolant p 130 Completely fill the radiator with coolant Mount radiator cap 2 Rest the vehicle on the side stand Danger Danger of poisoning Exhau...

Page 109: ...le optional The riding mode selected last appears in the display The riding mode can also be changed while riding with a closed throttle grip Info The riding mode selection does not influence the ABS...

Page 110: ...ustment can be set while riding with a closed menu using the UP or DOWN button Info The spin adjuster is only available in TRACK riding mode optional 18 4 Throttle response optional V01144 01 Possible...

Page 111: ...ng the engine oil and oil filter cleaning the oil screens Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden Wear suitable protective clothing and safety gloves...

Page 112: ...e sealing surfaces V01237 10 Insert new oil filter 5 Info Only insert the oil filter by hand Oil the O ring of the oil filter cover Position oil filter cover 4 Mount and tighten screws 3 Guideline Scr...

Page 113: ...wear of the engine H01066 10 Main work Remove filler plug 1 with the O ring and fill up with engine oil Fill engine oil to the middle of the level viewer Engine oil SAE 10W 50 p 130 Info In order to...

Page 114: ...ever until resistance is perceptible and deter mine the free travel A Free travel of clutch lever A 5 mm 0 2 in If the free travel of the clutch lever does not meet specifi cations Set the free travel...

Page 115: ...id direct sunshine when cleaning the motorcycle 401061 01 Close off exhaust system to keep water from entering Remove loose dirt first with a soft jet of water Spray the heavily soiled parts with a no...

Page 116: ...nd maintenance steps for winter operation Info If you use the motorcycle in winter salt can be expected on the roads You should therefore take precau tions against aggressive road salt After riding on...

Page 117: ...ens p 109 Check the antifreeze and coolant level p 101 Check tire pressure p 87 Remove the 12 V battery p 89 Charge the 12 V battery p 91 Guideline Storage temperature of the 12 V battery without dire...

Page 118: ...motorcycle off the front lifting gear p 65 Remove the rear of the motorcycle from the lifting gear p 64 Charge the 12 V battery p 91 Install the 12 V battery p 90 Set the time and date Perform checks...

Page 119: ...ocedure p 51 Engine has too little power Air filter is very dirty Remove the air filter Install the air filter Fuel filter is very dirty Check the fuel pressure Malfunction in the electronic fuel inje...

Page 120: ...screens p 109 Headlight and position light are not functioning Fuse 6 blown Change the fuses of individual electri cal power consumers p 95 Turn signal brake light and horn are not functional Fuse 5...

Page 121: ...ed light alloy Piston rings 1 compression ring 1 lower compression ring 1 oil ring with spring expander Engine lubrication Semi dry sump lubrication system with two trochoid pumps Primary transmission...

Page 122: ...bf ft Loctite 243 Screw shift shaft sensor M5 6 Nm 4 4 lbf ft Loctite 243 Screw thermostat case M5 6 Nm 4 4 lbf ft Loctite 243 Securing screw balancer shaft M5 5 Nm 3 7 lbf ft Loctite 243 Swing angle...

Page 123: ...9 lbf ft Loctite 243 Screw valve cover M6 10 Nm 7 4 lbf ft Screw water pump cover M6 10 Nm 7 4 lbf ft Loctite 243 Screw water pump wheel M6 10 Nm 7 4 lbf ft Loctite 243 Nut exhaust flange M8 15 Nm 11...

Page 124: ...rve tightening sequence 1st stage 5 Nm 3 7 lbf ft 2nd stage 15 Nm 11 1 lbf ft 3rd stage 90 4th stage 90 Screw support greased thread oiled Screw plug cylinder head oil drain M12x1 5 15 Nm 11 1 lbf ft...

Page 125: ...ting brake discs rear Disc brake with single piston brake caliper floating Brake discs diameter front 300 mm 11 81 in rear 240 mm 9 45 in Brake discs wear limit front 4 5 mm 0 177 in rear 4 5 mm 0 177...

Page 126: ...R 17 M C 58W TL J Continental ContiRoad 180 55 ZR 17 M C 73W TL G Continental ContiRoad The tires specified represent one of the possible series production tires Additional information is available in...

Page 127: ...s chassis M5 5 Nm 3 7 lbf ft Screw air filter box M5 3 Nm 2 2 lbf ft Screw brake fluid reservoir for rear brake M5 5 Nm 3 7 lbf ft Loctite 243 Screw combination instrument M5 4 Nm 3 lbf ft Screw combi...

Page 128: ...f ft Loctite 243 Screw fuel tank bracket M6 10 Nm 7 4 lbf ft Loctite 243 Screw fuel tank spoiler M6 3 Nm 2 2 lbf ft Screw ground wire on frame M6 6 Nm 4 4 lbf ft Screw ground wire to starter motor M6...

Page 129: ...ft Loctite 2701 Screw grab handle M8x50 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw main silencer fastening M8 15 Nm 11 1 lbf ft Screw main silencer holder M8x25 25...

Page 130: ...nd M10 35 Nm 25 8 lbf ft Loctite 243 Screw side stand bracket M10 45 Nm 33 2 lbf ft Loctite 243 Banjo bolt brake line M10x1 25 Nm 18 4 lbf ft Screw front brake caliper M10x1 25 45 Nm 33 2 lbf ft Locti...

Page 131: ...n website http www ktm com btrouter KTM AG hereby declares that the Immo641 wireless system conforms with the relevant guidelines The full text of the Declaration of Conformity is available at the fol...

Page 132: ...Only use coolant that complies with the requirements stated see specifications on the container and that has the relevant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must...

Page 133: ...ard classification SAE p 133 SAE 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 R...

Page 134: ...Clean Perfect finish and high gloss polish for paints Recommended supplier MOTOREX Moto Shine Preserving materials for paints metal and rubber Recommended supplier MOTOREX Moto Protect Special cleane...

Page 135: ...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 136: ...ts rear wheel locking with excessive engine braking effect by lightly opening the throttle valve KTM MY RIDE System for wireless communication with appropriate cellphones and headsets for telephony an...

Page 137: ...LIST OF ABBREVIATIONS 29 135 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 138: ...cs Come safely to a halt and contact an authorized KTM workshop ABS warning lamp lights up yellow Status or error messages relating to ABS TC indicator lamp lights up yellow MTC p 107 is not enabled o...

Page 139: ...ing 45 Combination instrument 22 43 ABS display 28 ABS Mode 40 activation and test 22 Anti wheelie mode optional 38 Audio player 42 Bluetooth 31 Clock Date 33 Consumption 32 coolant temperature indica...

Page 140: ...ing 76 Fork legs dust boots cleaning 65 Fork part number 13 Free travel of clutch lever checking 112 setting 112 Front rider s seat mounting 67 Front rider s seat removing 66 Front wheel installing 81...

Page 141: ...e schedule 61 62 Shift lever 20 basic position adjusting 47 basic position checking 46 Shifting 53 Shock absorber spring preload adjusting 63 Shock absorber article number 13 Side stand 21 Slip adjust...

Page 142: ...INDEX 140 Work rules 8...

Page 143: ...3214300en 3214300en 02 2021 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KISKA KTM...

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