KTM 990 Adventure Baja Owner'S Manual Download Page 97

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SERVICE WORK ON THE CHASSIS

11.13

Installing the crash bar

Info

The operations are the same for the left and right sides.

B01366-11

Main work

–

Position the crash bar and attach the clamp to the frame tube.

–

Mount screws

and

but do not tighten yet.

101563-11

–

Position the spacer and mount screw

–

Tighten screws

and

Guideline

Screw, crash bar

15 Nm
(11.1 lbf ft)

–

Tighten screw

Guideline

Remaining chassis screws

25 Nm
(18.4 lbf ft)

Finishing work

–

Raise the vehicle off of the center stand. (

p. 87)

Summary of Contents for 990 Adventure Baja

Page 1: ...OWNER S MANUAL 2013 990 Adventure Baja Art no 3211908en ...

Page 2: ......

Page 3: ... All specifications are non binding KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for delivery optio...

Page 4: ...According to the international quality management standard ISO 9001 KTM uses quality assurance processes that lead to the maximum possible quality of the products Issued by TÜV Management Service KTM Sportmotorcycle AG 5230 Mattighofen Austria ...

Page 5: ...23 3 6 Customer service 23 4 VIEW OF VEHICLE 24 4 1 View of vehicle front left side example 24 4 2 View of vehicle rear right side example 26 5 SERIAL NUMBERS 28 5 1 Chassis number 28 5 2 Type label 28 5 3 Key number 29 5 4 Engine number 30 5 5 Fork part number 30 5 6 Shock absorber part number 31 6 CONTROLS 32 6 1 Clutch lever 32 6 2 Hand brake lever 32 6 3 Throttle grip 33 6 4 Horn button 33 6 5...

Page 6: ...6 29 Side stand 57 6 30 Center stand 57 7 PREPARING FOR USE 58 7 1 Information on first use 58 7 2 Running in the engine 59 7 3 Loading the vehicle 60 8 RIDING INSTRUCTIONS 62 8 1 Checks and maintenance measures when preparing for use 62 8 2 Starting 63 8 3 Starting off 65 8 4 Shifting riding 65 8 5 Braking 68 8 6 Stopping parking 69 8 7 Transport 71 8 8 Refueling 72 9 SERVICE SCHEDULE 75 9 1 Serv...

Page 7: ...lic clutch 108 11 25 Removing the right underride guard 109 11 26 Installing the right underride guard 109 11 27 Removing the underride guard x 110 11 28 Installing the underride guard x 110 12 BRAKE SYSTEM 111 12 1 Checking the free travel of the hand brake lever 111 12 2 Adjusting the free travel of the hand brake lever 111 12 3 Checking the brake discs 112 12 4 Checking the front brake fluid le...

Page 8: ...e cable x 165 16 3 Ignition curve plug in connector 165 16 4 Adjusting the ignition curve to the fuel quality 166 17 SERVICE WORK ON THE ENGINE 167 17 1 Checking the engine oil level 167 17 2 Changing the engine oil and filter cleaning the oil screens x 168 17 3 Draining engine oil cleaning oil screens x 168 17 4 Removing the oil filter x 172 17 5 Installing the oil filter x 173 17 6 Filling up wi...

Page 9: ...TABLE OF CONTENTS 7 32 STANDARDS 218 INDEX 219 ...

Page 10: ...rstanding In the interest of your own safety have these jobs performed by an authorized KTM workshop There your motorcycle will be optimally cared for by specially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page 1 2 Formats used The typographical formats used in this document are explained below Specific name Identif...

Page 11: ...roads in the homologated version 2 2 Safety advice A number of safety instructions need to be followed to operate the vehicle safely Therefore read this manual carefully The safety instruc tions are highlighted in the text and are referred to at the relevant passages Info The vehicle has various information and warning labels at prominent locations Do not remove information warning labels If they ...

Page 12: ...that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken Warning Identifies a danger that will lead to environmental damage if the approp...

Page 13: ...11 ...

Page 14: ...2 SAFETY ADVICE 12 2 4 Overview of labels B01338 10 ...

Page 15: ...nformation on tires 3 USA type label 4 Information on emission control 4 Information on suspension tuning 4 Information on refueling 4 Information on chain tension 5 Information on noise emission 6 Canada type label 700210 01 Information on starting up ...

Page 16: ...2 SAFETY ADVICE 14 B01344 01 Information on tires B01340 01 USA type label ...

Page 17: ...2 SAFETY ADVICE 15 B01339 01 Information on emission control B01341 01 Information on suspension tuning ...

Page 18: ...2 SAFETY ADVICE 16 400630 01 Information on refueling 400628 01 Information on chain tension ...

Page 19: ...th you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying KTM North America Inc If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or K...

Page 20: ...America Inc Customer Support 1119 Milan Ave Amherst OH 44001 USA Phone 440 985 3553 www ktmusa com KTM Canada Inc Customer Support 1375 1 Marie Victorin Saint Bruno QC J3V 6B7 Phone 450 441 4451 x 4250 www ktmcanada com 2 7 Operating noise warning This product should be checked for necessary repairs or replacement parts if motorcycle noise has increased significantly through use Otherwise the owne...

Page 21: ...l of or puncturing the muffler baffles header pipes or any other components which conducts exhaust gases 2 Removal or puncturing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving part of the vehicle or parts of the exhaust or intake system with parts other than those specified by the manu facturer 2 10 Safe operation Danger Danger of accidents Danger arising from...

Page 22: ...creased safety risk Wear protective clothing helmet boots gloves pants and jacket with protectors every time you ride the vehicle Always wear protective clothing that is in good condition and meets the legal requirements In the interest of your own safety KTM recommends that you only operate the vehicle while wearing protective clothing 2 12 Work rules Special tools are necessary for some of the w...

Page 23: ...It is important that you read this Owner s Manual carefully and completely before making your first trip The Owner s Manual contains use ful information and many tips on how to operate handle and maintain your motorcycle Only then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to en...

Page 24: ... accessory products that are approved and or recommended by KTM and have them installed by an authorized KTM workshop KTM accepts no liability for other products and any resulting damage or loss Certain spare parts and accessory products are specified in parentheses in the descriptions Your KTM dealer will be glad to advise you The current KTM PowerParts for your vehicle can be found on the KTM we...

Page 25: ...ipment In the interest of clarity some components may be shown disassembled or may not be shown at all It is not always necessary to disassem ble the component to perform the activity in question Please follow the instructions in the text 3 6 Customer service Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM A list of authorized KTM dealers can b...

Page 26: ...4 VIEW OF VEHICLE 24 4 1 View of vehicle front left side example B01345 10 ...

Page 27: ...ver p 32 3 Tool set p 53 4 Seat lock p 53 5 Luggage rack plate p 54 6 Handrails p 54 7 Fork compression adjustment 8 Fuel taps p 52 9 Engine number p 30 10 Side stand p 57 11 Shift lever p 55 12 Shock absorber compression adjustment 13 Center stand p 57 14 Passenger footrests p 55 ...

Page 28: ...4 VIEW OF VEHICLE 26 4 2 View of vehicle rear right side example B01346 10 ...

Page 29: ... Hazard warning flasher switch hazard warning flasher p 47 3 Ignition steering lock p 36 4 Socket for electrical accessories p 48 5 Emergency OFF switch p 35 5 Electric starter button p 36 6 Hand brake lever p 32 7 Chassis number p 28 8 Shock absorber rebound adjustment 9 Foot brake lever p 56 10 Oil dipstick 11 Compensating tank cooling system ...

Page 30: ...100542 10 The chassis number 1 is stamped on the right side of the steering head The chassis number is also found on the type label 5 2 Type label B00891 10 The USA 1 type label is located on the right frame tube in the area of the oil tank ...

Page 31: ... key number Code 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 Use the orange programming key to activate and deactivate the black ignition key Keep the orange programming key in a safe place it must only be used for learning and programming functions ...

Page 32: ...30 5 4 Engine number 100544 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket 5 5 Fork part number 100545 10 The fork part number 1 is stamped on the inner side of the fork stub ...

Page 33: ...5 SERIAL NUMBERS 31 5 6 Shock absorber part number 100546 10 The shock absorber part number 1 is stamped on the upper part of the shock absorber ...

Page 34: ...er 1 is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 6 2 Hand brake lever 100506 10 The hand brake lever 1 is fitted on the right side of the handlebar The front brake is engaged using the hand brake lever ...

Page 35: ...ottle grip 1 is fitted on the right side of the handlebar 6 4 Horn button 100510 10 The horn button 1 is fitted on the left side of the handlebar Possible states Horn button in neutral position Horn button pressed The horn is operated in this position ...

Page 36: ... light are switched on High beam on The light switch is turned upwards In this position the high beam and tail light are switched on 6 6 Headlight flasher switch 100508 10 The headlight flasher switch 1 is fitted on the left side of the handlebar Possible states Headlight flasher switch in neutral position Headlight flasher switch pressed The headlight flasher switch high beam is oper ated in this...

Page 37: ... pressed to the right The turn signal switch automatically returns to the central position after use To switch off the turn signal press the turn signal switch towards the switch case 6 8 Emergency OFF switch 100547 10 The emergency OFF switch 1 is fitted on the right side of the handlebar Possible states Emergency OFF switch off In this position the ignition circuit is inter rupted a running engi...

Page 38: ...riple clamp Info The ignition may only be switched on using a black ignition key Use the orange programming key to activate and deactivate the black ignition key Possible states Ignition OFF In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start The black ignition key can be removed Ignition ON In this position the ignition circuit is cl...

Page 39: ...ys to a single key ring this may cause mutual interference and lead to problems A lost black ignition key must be deactivated to prevent unauthorized persons from operat ing the vehicle The second black ignition key is activated when the vehicle is shipped Another two spare ignition keys key number on the KEYCODECARD can be ordered from an authorized KTM workshop but they need to be activated for ...

Page 40: ... trip master 1 TRIP 1 trip mas ter 2 TRIP 2 and the ambient temperature Press the SET button 2 to reset the trip master 1 function TRIP 1 and trip master 2 func tion TRIP 2 to 0 0 Button 3 has no function 6 12 3 Tachometer 400916 10 The tachometer 1 shows the engine speed in revolutions per minute The red marking 2 shows the overspeed range of the engine ...

Page 41: ...switched on The temperature warning lamp lights up red The coolant temperature has reached a critical value The fuel level warning lamp lights up orange The fuel level has reached the reserve mark The display switches to TRIP F The oil pressure warning lamp lights up red The oil pressure is too low FI warning lamp MIL lights up flashes orange The OBD on board diagno sis has detected an emission or...

Page 42: ... light up for one second as a function test 400837 01 LEnGth Following the display function test the wheel circumference LEnGth is shown for one sec ond Info 2205 mm equals the circumference of the 21 front wheel with a series production tire The display then changes to the last selected mode ...

Page 43: ... is shown in kilometers per hour km h or in miles per hour mph 6 12 7 Setting kilometers or miles Info If you change the unit the value ODO is retained and converted accordingly Making the setting according to the country Condition The motorcycle is standing ...

Page 44: ... until the ODO mode is active Keep the MODE button pressed until the display mode changes from km h to mph or from mph to km h 6 12 8 Time 400893 11 The time is shown in area 1 of the display Info After reconnecting the battery or changing the fuse the time must be reset 6 12 9 Setting the clock Condition The motorcycle is standing ...

Page 45: ...button and the SET button pressed simultaneously The time is set 6 12 10 ODO display 400839 01 In the ODO display mode the total distance traveled is shown in kilometers or miles Info This value is retained even if the battery is disconnected and or the fuse blows 6 12 11 Setting resetting display TRIP 1 Info The TRIP 1 trip counter is always running and counts up to 999 9 The trip counter can be ...

Page 46: ...RIP 2 Info The TRIP 2 trip counter is always running and counts up to 999 9 The trip counter can be used to measure the distance covered during trips or between two refueling stops After the value 999 9 is reached the trip counter starts at 0 0 again 400841 01 Switch on the ignition by turning the black ignition key to the position ON Press the MODE button repeatedly until the TRIP 2 mode is activ...

Page 47: ...RIP F and starts to count from 0 0 regardless of the previous display mode Info The low fuel warning lamp lights up in parallel to the TRIP F display 6 12 14 Ambient temperature indicator 400893 13 The ambient temperature 1 is displayed in C or F 6 12 15 Setting the temperature unit of measure Condition The motorcycle is standing ...

Page 48: ...he display mode changes from C to F or from F to C 6 12 16 Warning of icy roads 400894 10 The ice symbol lights up to indicate an increased danger of slippery roads The ice symbol appears in the display when the ambient temperature drops below the specified value Temperature 3 C 37 F The ice symbol goes out in the display when the ambient temperature rises above the specified value again Temperatu...

Page 49: ...switch hazard warning flasher B00116 11 The hazard warning flasher switch 1 is found to the left of the combination instrument The hazard warning flasher is used to indicate emergency situations Info The hazard warning flasher can be activated or deactivated while the ignition is switched on or up to 30 seconds after the ignition is switched off To spare battery power only press the hazard warning...

Page 50: ... that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with wat...

Page 51: ...gnition key breakage To take pressure off of the ignition key push down on the filler cap Damaged igni tion keys must be replaced Turn the ignition key 90 clockwise Raise the filler cap withdraw the ignition key and open the second filler cap Remove the ignition key Info The motorcycle is equipped with two fuel tanks and two filler necks The fuel tanks are connected to each other with a fuel line ...

Page 52: ...hat it is closed correctly Change cloth ing that came into contact with fuel Immediately clean skin that came into contact with fuel using soap and water Push the filler caps closed until the locks engage Close the covers 6 17 Unlocking the storage compartment B01351 10 Insert the ignition key into the seat lock Turn the ignition key to position B Remove the ignition key ...

Page 53: ... Turn the ignition key to position A Remove the ignition key 6 19 Opening the storage compartment B01353 10 Unlock the storage compartment p 50 Press button 1 toward the seat and raise the cover at the same time Info The storage compartment can only be opened if it was first unlocked using the seat lock ...

Page 54: ...524 10 There is a fuel tap 1 on every fuel tank Info The fuel taps must be open during operation The fuel taps are only closed when dismantling the fuel tank Possible states Fuel supply closed The knurled screws are turned clockwise as far as possible The level cannot be compensated and no fuel can flow out of the fuel tank Fuel tap open The knurled screws are turned counterclockwise as far as pos...

Page 55: ...s and unlocks the storage compartment Possible states A Storage compartment locked B Storage compartment unlocked C Seat unlocked The seat lock can be locked with the ignition key 6 23 Tool set B01355 10 The tool set 1 is located in the storage compartment under the seat The extension 2 can be mounted on several of the wrenches in the tool set ...

Page 56: ... trip 6 25 Luggage rack plate B01356 11 The luggage rack plate 1 is located behind the seat The base plate of a luggage system optional can be attached to the luggage rack plate The luggage rack plate may not be loaded with more than the specified weight Maximum permissible load on luggage rack plate 8 kg 18 lb Info Note the information provided by the luggage manufacturer ...

Page 57: ...r footrests can be folded up and down Possible states Passenger footrests folded up For operation without a passenger Passenger footrests folded down For operation with a passenger 6 27 Shift lever 100526 10 Shift lever 1 is mounted on the left side of the engine ...

Page 58: ...can be seen in the photograph The neutral or idle position is between the first and second gears 6 28 Foot brake lever 100525 10 Foot brake lever 1 is located in front of the right footrest The rear brake is activated using the foot brake lever ...

Page 59: ...ycle use Side stand is coupled with the safety start system see the riding instructions Possible states Side stand folded out The vehicle can be leaned on the side stand The safety start system is active Side stand folded in This position is mandatory for all trips The safety start system is inactive 6 30 Center stand B01359 10 The vehicle is equipped with a center stand 1 in addition to a side st...

Page 60: ... of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the correspon...

Page 61: ...service record at vehicle handover Before your first trip read the entire operating instructions carefully Get to know the controls Adjust the basic setting of the clutch lever p 108 Adjust the free travel of hand brake lever p 111 Adjust the basic position of foot brake lever x Get used to handling the motorcycle on a suitable piece of land before making a longer trip Try also to ride as slowly a...

Page 62: ...helmet baggage Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and or tank rucksack Mount and secure suitcase and tank rucksack according to the manufacturer s instructions Warning Danger of accidents Unstable handling characteristics at high speed Adapt your speed according to your payload Ride more slowly if your motorcycle is loaded with cases...

Page 63: ...table handling characteristics due to slipped baggage Check the way your baggage is fixed regularly Warning Danger of burns A hot exhaust system can burn baggage Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system If you are carrying baggage make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distri bution...

Page 64: ...nt brake linings p 115 Check the rear brake linings p 119 Check that the brake system is functioning properly Check the coolant level in the compensating tank p 158 Check the chain for dirt p 100 Check the chain tension p 102 Check the tire condition p 128 Check the tire air pressure p 129 Check the spoke tension p 130 Check the settings of all controls and ensure that they can be operated smoothl...

Page 65: ...in an enclosed space without an effective exhaust extraction system Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic components and safety equipment may be damaged Never operate the vehicle with a discharged battery or without a battery Note Engine failure High engine speeds in cold engines have a negative effect on the service life o...

Page 66: ... the electric starter button until the function test of the combination instrument is finished When starting DO NOT open the throttle If you open the throttle during the start ing procedure fuel is not injected by the engine management system and the engine cannot start Press the starter for a maximum of 5 seconds Wait for a least 5 seconds before trying again This motorcycle is equipped with a sa...

Page 67: ... a low gear at high engine speed The engine races and the rear wheel can lock up Warning Danger of accidents Malfunctions caused by incorrect ignition key position Do not change the ignition key position during a journey Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle Make all adjustments when the vehicle is at a standstill Warning Risk of injury Falling...

Page 68: ...rface must be rough ened in the first 200 kilometers 124 3 miles by moderate riding at alternating angles The full grip levels are not achieved until the tires have been run in Warning Danger of accidents Unstable handling characteristics Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational and with a full tank driver and passenger with pr...

Page 69: ...aneously pulling the clutch lever shift into the next gear release the clutch and open the throttle Info You can see the positions of the six forward gears in the figure The neutral or idle position is between the first and second gears First gear is used for starting off or for steep inclines The operating temperature is reached when 6 bars of the temperature indicator light up After reaching max...

Page 70: ...ault If the ice symbol appears in the combination instrument the streets may be icy Adjust your speed to the road conditions 8 5 Braking Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a dirty or wet brake system by riding and braking gently Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear...

Page 71: ...ion and the road conditions When braking first throttle back and then apply the front and rear brakes at the same time On sandy wet or slippery surfaces use the rear brake Braking should always be completed before you enter a bend Change down to a lower gear that is appropriate for your speed On long downhill stretches use the braking effect of the engine Do this by changing down two gears but do ...

Page 72: ... let the vehicle cool first Note Material damage Damage and destruction of components by excessive load The side stand is designed for the weight of the motorcycle only Do not sit on the motorcycle when it is supported by the side stand only The side stand and or the frame could be damaged and the motorcycle could fall over Note Material damage Damage and destruction of components from excessive l...

Page 73: ...as it will go and rest the vehicle on it Alternative 2 Raise the vehicle using the center stand p 86 Lock the steering by turning the handlebar to the left pressing the black ignition key down in the position OFF and turning it to the position To engage the steering lock more easily move the handlebars gently back and forth Remove the black ignition key 8 7 Transport Note Danger of damage The park...

Page 74: ... escape if the tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact of the fuel with skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc tor immediately Change ...

Page 75: ...easurement of A 75 mm 2 95 in Fill the left fuel tank no higher than the lower edge of the filler neck Total fuel tank capacity approx 20 l 5 3 US gal Super unleaded ROZ 95 RON 95 PON 91 p 214 Info If the right fuel tank is filled to the filler neck fuel may run out of the motorcy cle if parked on the side stand and the fuel becomes warm Close the filler caps p 50 When using low octane fuel Note E...

Page 76: ...ality p 166 400913 12 Press the SET button 2 for two seconds The fuel level warning lamp 1 switches off TRIP F is set to 0 0 and the previous display mode appears Info If you do not press the SET button 2 the reset takes place automatically after about three minutes ...

Page 77: ...ke linings p 119 Check the brake discs p 112 Check that the brake lines are undamaged and free of leaks Check the rear brake fluid level p 117 Check the free travel of the foot brake lever p 116 Check that the shock absorber and fork are leak tight Perform a fork service and shock absorber service as needed and depending on how the vehicle will be used Check the swingarm bearing x Check the wheel ...

Page 78: ...tifreeze and coolant level p 155 Check the wiring harness of the throttle valve body for damage and correct routing x Check the cables for damage and kink free routing x Check the control cables for damage kink free routing and adjustment Change the air filter Clean the air filter box x Check the fuel pressure x Check the value of the manifold absolute pressure sensor PM value with the KTM diagnos...

Page 79: ...the vehicle is roadworthy and take a test ride Read out the error memory after the test ride using the KTM diagnostics tool x Make the necessary service entries in the KTM DEALER NET and service record x K10N Once after 1 000 km 621 4 mi K75A Every 7 500 km 4 660 mi or annually K150A Every 15 000 km 9 321 mi or every 2 years K300A Every 30 000 km 18 641 mi or every 4 years ...

Page 80: ... personal suspension adaptation Do not change the adjustments at random or by more than 40 since otherwise the riding characteristics could deteriorate particularly at high speeds 10 2 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior B01360 10 Remove protection covers 1 Turn adjusting screws 2 clockwise all the way Info Th...

Page 81: ... damping Mount protection covers 1 10 3 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork rebound behavior 100534 10 Turn adjusting screws 1 clockwise all the way Info The adjusting screws are located at the top end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise by the number of clicks corresponding to the fork ...

Page 82: ...ounterclockwise to reduce damping 10 4 Adjusting the spring preload of the fork B00554 10 Turn adjusting screws 1 counterclockwise all the way Info Make the same adjustment on both fork legs Turn back clockwise by the number of turns corresponding to the fork type Guideline Spring preload Preload Adjuster Comfort 5 turns Standard 5 turns Sport 8 turns Full payload 7 turns ...

Page 83: ... on the landing after a jump the rear wheel suspension compresses more quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses more slowly These two ranges can be adjusted separately although the transition between high speed and low speed is gradual Thus changes in the high speed range affect the compression damping in the l...

Page 84: ...clicks Sport 15 clicks Full payload 15 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 10 7 Adjusting the high speed compression damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop wi...

Page 85: ...amping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce damping 10 8 Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your a...

Page 86: ...amping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 10 9 Adjusting the spring preload of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your autho...

Page 87: ...er of turns corresponding to the shock absorber type and use Guideline Spring preload Preload Adjuster Comfort 4 turns Standard 4 turns Sport 8 turns Full payload 16 turns Info The handwheel can be swung out to make settings Turn clockwise to increase the spring preload turn counterclockwise to reduce the spring preload ...

Page 88: ...ile it is resting on the center stand The center stand or frame could be damaged and the motorcycle could fall over Pull the motorcycle up onto the center stand using the handrail and not the handwheel of the shock absorber adjustment The shock absorber could become leaky B01363 10 Position yourself to the left of the vehicle Hold the handlebar with the left hand and press the center stand onto th...

Page 89: ...icle on a firm and even surface B01364 01 Unlock the steering and move the vehicle forward with both hands on the handlebar As the vehicle moves off of the center stand activate the front brake to prevent the vehicle from rolling Check that the center stand is folded all the way up 11 3 Bleeding the fork legs Preparatory work Raise the vehicle using the center stand p 86 ...

Page 90: ...365 10 Main work Push dust boot 1 of both fork legs downwards Info The dust boots should remove dust and coarse dirt particles from the fork tubes Over time dirt can penetrate behind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil ...

Page 91: ...lad to help Info If the vehicle is operated for a lengthy period with play in the steering head bearing the bearings and the bearing seats in the frame can become damaged over time Preparatory work Raise the vehicle using the center stand p 86 B00115 01 Main work Bear down on the rear of the vehicle or raise it on the underride guard The front wheel is not in contact with the ground Move the handl...

Page 92: ...g head bearing play x Check the steering head bearing and adjust if necessary 11 6 Removing the front side cover Info The operations are the same on the left and right sides B00893 10 Remove screws 1 Carefully swing out the side cover 2 at the top and disconnect the plug in connectors of the turn signal cables Pull off the overflow hose of the fuel tank and take off the trim 11 7 Installing the fr...

Page 93: ...of the fuel tank to the connector Connect the plug in connectors of the turn signal cables and swing the side cover up toward the vehicle Mount and tighten screws 2 with the washers Guideline Remaining chassis nuts M6 10 Nm 7 4 lbf ft Check the function of turn signal 11 8 Removing the radiator guard 100641 10 Remove screws 1 and radiator guard 2 ...

Page 94: ... This ensures that all required parts are available when needed 11 9 Installing the radiator guard 0 0 5 5 0 0 1 1 0 0 1 1 0 0 2 2 0 0 3 3 0 0 4 4 100639 10 Place nuts 1 onto tabs 2 of the radiator Hook radiator guard 3 into holes 4 at the bottom and swing up to the radiator Mount and tighten screws 5 Guideline Remaining chassis nuts M6 10 Nm 7 4 lbf ft ...

Page 95: ...tion key 11 11 Mounting the seat 0 0 3 3 0 0 1 1 0 0 2 2 100505 10 Hook projection 1 of the seat into the storage compartment lower the seat at the rear and push it forward at the same time The two projections 2 must be inserted into the frame Push locking pin 3 into the lock housing and push the back of the seat down until the locking pin locks in place with an audible click Finally check that th...

Page 96: ...crash bar x Info The operations are the same for the left and right sides Preparatory work Raise the vehicle using the center stand p 86 101563 10 Main work Remove screw 1 B01366 10 Remove screws 2 and 3 and take off the crash bar Remove the front spacer ...

Page 97: ...ition the crash bar and attach the clamp to the frame tube Mount screws 1 and 2 but do not tighten yet 101563 11 Position the spacer and mount screw 3 Tighten screws 1 and 2 Guideline Screw crash bar M8 15 Nm 11 1 lbf ft Tighten screw 3 Guideline Remaining chassis screws M8 25 Nm 18 4 lbf ft Finishing work Raise the vehicle off of the center stand p 87 ...

Page 98: ... p 51 Remove screws 1 Carefully remove the storage compartment and swing it to the right Place a cloth between the right fuel tank and the storage compartment to prevent damage 11 15 Installing the storage compartment x B01367 10 Main work Remove the cloth and position the storage compartment Mount and tighten screws 1 Finishing work Close the storage compartment p 52 Mount the seat p 93 ...

Page 99: ...d skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc tor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister according to regulations and keep it out of the reach of children Preparator...

Page 100: ...2 and fuel pump 3 Detach hose 4 Disconnect fuel hose connection 5 Info Remaining fuel may flow out of the fuel hose Push the hose clamp toward the rear and pull fuel hose 6 off of the fuel tap Take off the fuel tank 11 17 Installing the left fuel tank x Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first...

Page 101: ...in a suitable canister according to regulations and keep it out of the reach of children Preparatory work Clean the fuel hose connection and check the O ring for damage 100618 11 Main work Hold the fuel tank at roughly the installation height to connect the hoses and plug in connections Attach fuel hose 1 to the fuel tap and push the hose clamp forward Join fuel hose connection 2 Attach hose 3 to ...

Page 102: ...rclockwise as far as possible Check the fuel system for leakage Install the crash bar x p 95 Raise the vehicle off of the center stand p 87 11 18 Checking for chain dirt 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 100 11 19 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with ...

Page 103: ...ntal hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info The service life of the chain depends largely on its maintenance 400725 01 Clean the chain regularly Rinse off loose dirt with a soft jet of water Remove old grease remains with chain cleaner Chain cleaner p 215 After drying...

Page 104: ...On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check the chain tension and correct if necessary 0 0 B B 0 0 A A 400620 10 Lean the motorcycle on the side stand Shift the transmission to neutral Push the chain upwards near the lower chain guard screw and measure chain tension A Info The upper chain secti...

Page 105: ...et rear sprocket bearings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check the chain tension and correct if necessary Preparator...

Page 106: ...eft and right chain adjuster 4 are in the same position in relation to reference marks C The rear wheel is then correctly aligned Info The upper chain section must be taut Chain wear is not always even so you should check the setting at different chain positions Tighten nuts 2 Make sure that chain adjusters 4 are resting against adjusting screws 3 Tighten nut 1 Guideline Nut rear wheel spindle M25...

Page 107: ...et Preparatory work Raise the vehicle using the center stand p 86 100132 10 Main work Check the rear sprocket and engine sprocket for wear If the rear sprocket or engine sprocket is worn Change the power set x Info The rear sprocket engine sprocket and chain should always be changed together ...

Page 108: ...he lower chain section Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance B at the longest chain section 272 mm 10 71 in If distance B is greater than the specified measurement Change the power set x Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out faster on old worn...

Page 109: ...d is loose Fully tighten the chain sliding guard Guideline Screw chain sliding guard M6 6 Nm 4 4 lbf ft Loctite 243 B00114 01 Check the chain guide for wear If the chain guide is worn Change the chain guide x Check the chain guide for tightness If the chain guide is loose Fully tighten the chain guide Guideline Screw chain guide M6 6 Nm 4 4 lbf ft Loctite 243 Finishing work Raise the vehicle off o...

Page 110: ...justment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 11 24 Checking rectifying the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc Do not use brake fluid 100620 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Rem...

Page 111: ...ghten the screws 11 25 Removing the right underride guard 100581 10 Remove screws 1 Remove the right underride guard 2 11 26 Installing the right underride guard 100581 11 Position right underride guard 1 Mount and tighten screws 2 Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft ...

Page 112: ...ork Swing the side stand downward Remove all four screws 1 and take off underride guard 2 11 28 Installing the underride guard x 100578 10 Main work Position underride guard 1 Mount and tighten screws 2 Guideline Screw underride guard M8 25 Nm 18 4 lbf ft Loctite 243 Swing up the side stand Finishing work Raise the vehicle off of the center stand p 87 ...

Page 113: ...the free travel on hand brake lever according to specifications 100555 10 Push the hand brake to the handlebar and check the free travel A Free travel of hand brake lever 3 mm 0 12 in If the free travel does not meet specifications Adjust the free travel of hand brake lever p 111 12 2 Adjusting the free travel of the hand brake lever 100556 10 Check the free travel of the hand brake lever p 111 Ad...

Page 114: ...nts while riding 12 3 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc s Change the worn brake disc s without delay Your authorized KTM workshop will be glad to help 400618 10 Check the thickness of the front and rear brake discs in several places to ensure that it conforms to measurement A Info Wear reduces the thickness of the brake disc in a...

Page 115: ... in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help 100557 10 Move the brake fluid reservoir...

Page 116: ...with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel...

Page 117: ...ed or spilt brake fluid immediately with water 12 6 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help Note Danger of accidents Reduced braking efficiency caused by damaged brake discs If the brake linings are not changed in time the steel brake ...

Page 118: ...If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to over heating Adjust the free travel on foot brake lever according to specifications 100602 10 Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel A Guideline Free travel at foot brake lever 3...

Page 119: ...ge the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help 100560 10 Raise the vehicle using the center stand p 86 Check the brake fluid level of the brake fluid reservoir If the fluid level reaches the MIN mark 1 Add rear brake fluid x p 117 12 9 Adding rear brake fluid x Warning Danger of accidents Failure of the brake syste...

Page 120: ...ake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in...

Page 121: ...luid DOT 4 DOT 5 1 p 211 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid immediately with water 12 10 Checking the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help ...

Page 122: ...rake disc The braking effect is greatly reduced and the brake discs are destroyed Check the brake linings regularly B01369 10 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings x Check the brake linings for damage and cracking If there is wear or tearing Change the rear brake linings x ...

Page 123: ...ck the brake pis tons B01372 10 Loosen screws 4 and 5 Unscrew screw 4 about six turns and press your hand on the screw to push the wheel spindle out of the axle clamp Warning Danger of accidents Reduced braking efficiency due to damaged brake discs Always lay down the wheel in such a way that the brake discs are not dam aged Holding the front wheel withdraw the wheel spindle Swing the brake calipe...

Page 124: ...on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary B01373 11 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the wheel bearing x Clean and grease the shaft seal rings 1 and bearing surface A of the spacers Long life grease p 216 Insert the spacers ...

Page 125: ...aise the vehicle off of the center stand p 87 Pull the front wheel brake and push down hard on the fork several times to align the fork legs Fully tighten screws 3 Guideline Screw fork stub M8 15 Nm 11 1 lbf ft 13 3 Removing the rear wheel x Preparatory work Raise the vehicle using the center stand p 86 B01374 10 Main work Press the brake caliper by hand on to the brake disc in order to press back...

Page 126: ...ake the chain off of the rear sprocket and place it on chain sprocket guard 6 Warning Danger of accidents Reduced braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not dam aged Holding the rear wheel withdraw the wheel spindle Take the rear wheel out of the swing arm Info Do not operate the foot brake when the rear wheel is removed Remove...

Page 127: ...heel always operate the foot brake until the pressure point is reached Main work Check the rear hub rubber dampers x p 126 B01377 10 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the wheel bearing x Clean and grease shaft seal ring 1 and bearing surface A of the spacer Long life grease p 216 Clean and grease the thread of the wheel spindle and nut Long ...

Page 128: ...e correctly aligned the markings on the left and right chain adjusters must be in the same position relative to the reference marks B Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Thread greased Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a pressure point Finishing work Raise the vehicle off of the center stand p 87 13 5 Checking the rear h...

Page 129: ...hub B01378 10 Lay the rear wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub To check the play A hold the rear wheel tight and try to rotate the rear sprocket Info Measure the play on the outside of the rear sprocket Play in rubber dampers rear wheel 5 mm 0 2 in If clearance A larger than the specified value Change all rubber dampers in the rear hub...

Page 130: ...ontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Warning Danger of accidents Reduced road grip with new tires New tires have a smooth rolling surface and therefore cannot provide full road grip The entire rolling surface must be rough ened in the first 200 kilometers 1...

Page 131: ...tires Info The tire s date of manufacture is usually part of the tire markings and is indi cated by the last four digits of the DOT marking The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture KTM recommends that the tires be changed after 5 years at the latest regard less of the actual state of wear If a tire is more than five years old Change...

Page 132: ...t meet specifications Correct the tire pressure Mount the dust cap 13 8 Checking spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that the spoke tension is correct Your authorized KTM workshop will be glad to help Info A loose spoke can cause wheel imbalance leading to more loose spokes in a short time If the spokes are too tight they can break due ...

Page 133: ...he frequency of the sound is a function of the spoke length and spoke diame ter If spokes of the same length and diameter vibrate with a different tone this is an indication that the spoke tensions differ You should hear a high note If the spoke tension differs Correct the spoke tension x ...

Page 134: ...nd battery gases Keep the battery away from sparks or open flames Charge only in well ventilated areas In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Preparatory work Switch off all power consumers and the engine Raise the vehicle using the center stand p 86 Remove the underride guard ...

Page 135: ...tray 5 Info Never operate the motorcycle with a discharged battery or without a battery In both cases electrical components and safety equipment can be damaged The vehicle is then no longer safe to ride 14 2 Installing the battery x 100580 11 Main work Insert the battery into battery tray 1 Slide the battery with the battery tray into the battery compartment Connect plus cable 2 Connect minus cabl...

Page 136: ...ry x Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep the battery away from sparks or open flames Charge only in well ventilated areas In the event of skin contact rinse with large amounts of water If battery acid gets in...

Page 137: ...id recharging with a high charging current shortens the battery s service life If the charging current charging voltage and charging time are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended peri...

Page 138: ...ntial and start potential of the battery and to test the alternator With this device you cannot overcharge the battery Switch off and disconnect the battery charger after charging Guideline Charge the battery regularly when the motorcycle is not in use 3 months Mount the red protection cap of the positive terminal extension Finishing work Install the right underride guard p 109 14 4 Changing the m...

Page 139: ...ay 1 off of the holder and remove protective cover 2 100584 10 Remove the faulty main fuse 3 Info A defective fuse can be identified by the burned out fuse wire A A reserve fuse 4 is located in the starter relay The main fuse protects all power consumers of the vehicle Install a new main fuse Fuse 58011109130 p 202 Check that the electrical equipment is functioning properly Mount the protective co...

Page 140: ...g the fuses in the fuse box Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Info The fuse box containing the fuses of remaining power consumers is located in the storage compartment Preparatory work Switch off all power consumers and the engine Open the storage compartment p 51 ...

Page 141: ... A high beam low beam parking light license plate lamp Fuse HORN BRAKE LIGHT 10 A horn brake light hazard warning flasher Fuse FAN 10 A radiator fan Fuse POWER RELAY 10 A ignition EFI control unit Fuse ACC1 CLOCK 10 A combination instrument socket supplementary devices permanent positive alarm system optional Fuse ACC2 10 A supplementary equipment accessories connected to the ignition switch Fuse ...

Page 142: ...fuse box so that it is available if needed Check that the power consumers are functioning Close the fuse box cover Finishing work Close the storage compartment p 52 14 6 Removing the headlight mask with the headlight Preparatory work Switch off all power consumers and the engine Remove the front side cover p 90 100590 10 Main work Unhook the headlight mask from the cockpit holder and remove it tow...

Page 143: ...t cloth to prevent the headlight and trim disc from being damaged 14 7 Installing the headlight mask with the headlight 100591 10 Main work Connect plug in connector 1 Check the lighting function Position the headlight mask Finishing work Install the front side cover p 90 Check the headlight setting p 148 ...

Page 144: ...porate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off all power consumers and the engine Remove the front side cover p 90 Remove the headlight mask with the headlight p 140 100647 10 Main work Remove rubber cap 1 and connector 2 from the bulb ...

Page 145: ... mount the rubber cap Finishing work Install the headlight mask with the headlight p 141 Install the front side cover p 90 Check the headlight setting p 148 14 9 Changing the parking light bulb in the headlight Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Pre...

Page 146: ...ing light W5W socket W2 1x9 5d p 202 Replace the rubber cap Finishing work Install the headlight mask with the headlight p 141 Install the front side cover p 90 Check the headlight setting p 148 14 10 Changing the turn signal bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease...

Page 147: ... the socket and turn it clockwise until it stops Turn signal RY10W socket BAU15s p 202 Check the turn signal to make sure it is functioning properly Position the diffuser Info Hook in projection A at recess B Insert the screw and first turn it counterclockwise until it engages in the thread Tighten the screw slightly 14 11 Changing the tail light bulb Note Damage to reflector Reduced brightness Gr...

Page 148: ... Tail light W5W socket W2 1x9 5d p 202 Insert the bulb sockets into the tail light Check the lighting function Position the tail light Mount and tighten the nuts with the washers Guideline Nut tail light M6 8 Nm 5 9 lbf ft 14 12 Changing the brake light bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lam...

Page 149: ...lb 3 carefully into the socket turn it counterclockwise by about 30 and pull it out of the socket Press the new bulb carefully into the socket and turn it clockwise until it stops Brake light P21W socket BA15s p 202 Insert the bulb socket into the tail light and turn clockwise until it stops Check the lighting function Position the tail light Mount and tighten nuts with the washers Guideline Nut t...

Page 150: ...ically in front of the wall and switch on the low beam headlight Guideline Distance A 5 m 16 ft The rider with luggage and passenger if applicable now mounts the motorcycle Check the headlight setting The light dark boundary must lie exactly on the lower mark when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applicable If the boundary between ...

Page 151: ...ting deactivating the ignition key Info The orange programming key must only be used for activating and deactivating If a black ignition key is lost or needs to be replaced the individual black ignition keys need to be enabled or disabled using the orange programming key This will also prevent the vehicle from being operated without authorization with the lost black ignition key You can activate o...

Page 152: ...Switch off the ignition by turning the orange programming key to the OFF position Pull out the orange programming key Insert the black ignition key in the ignition lock Switch on the ignition by turning the black ignition key to the position ON FI warning lamp MIL lights up switches off and then starts to flash The immobilizer indicator lamp lights up switches off briefly and switches on again Swi...

Page 153: ...ion key Turn the emergency OFF switch to the position 400919 10 Insert the orange programming key in the ignition lock Switch on the ignition by turning the orange programming key to the ON position FI warning lamp MIL lights up switches off and then starts to flash Immobilizer indicator lamp lights up Switch off the ignition by turning the orange programming key to the OFF position Switch on the ...

Page 154: ...tch off the ignition by turning the orange programming key to the OFF position Pull out the orange programming key Insert the black ignition key in the ignition lock Switch on the ignition by turning the black ignition key to the position ON FI warning lamp MIL lights up switches off and then starts to flash The immobilizer indicator lamp lights up switches off briefly and switches on again Switch...

Page 155: ...umber of flashes equals the number of functional black ignition keys including the orange programming key Switch off the ignition by turning the orange programming key to the OFF position Pull out the orange programming key All black ignition keys are activated included in this job sequence are activated ...

Page 156: ...nt temperature without causing any malfunctions 125 C 257 F 400619 11 Cooling takes place by means of the air stream and a radiator fan 3 which is controlled by a thermoswitch The lower the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect The heat expansion causes the surplus coolant to flow into the compensating tank 2 When the temperature falls this surplus coo...

Page 157: ...ling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soa...

Page 158: ...eck the coolant level in the compensating tank The coolant level must be between MIN and MAX If there is no coolant in the compensating tank Check the cooling system for leaks x Info Do not start up the motorcycle Fill bleed the cooling system x p 161 If the coolant in the compensating tank is not at the required level but the tank is not empty Add coolant to the MAX marking Alternative 1 Coolant ...

Page 159: ...y filled If the coolant level does not meet specifications Coolant loss 0 50 l 0 53 qt Check the cooling system for leaks x Info Do not start up the motorcycle Correct the coolant level Alternative 1 Coolant p 211 Alternative 2 Coolant mixed ready to use p 211 If the coolant level does not meet specifications Coolant loss 0 50 l 0 53 qt Check the cooling system for leaks x Info Do not start up the...

Page 160: ... engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor im...

Page 161: ...is not at the required level but the tank is not empty Remove the compensating tank cap Add coolant to the MAX marking Alternative 1 Coolant p 211 Alternative 2 Coolant mixed ready to use p 211 Mount the cap of the compensating tank 15 4 Draining the coolant x Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radia...

Page 162: ...n Condition The engine is cold Preparatory work Raise the vehicle using the center stand p 86 Switch off all power consumers and switch off the engine Remove the crash bar x p 94 Turn the knurled screws on both fuel taps clockwise as far as possible Remove the front side cover p 90 Remove the seat p 93 Remove the storage compartment and hang it to one side x p 96 Remove the left fuel tank x p 97 1...

Page 163: ...em x Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolant out of the re...

Page 164: ... To make sure that all of the air can escape from the cooling system raise the front of the vehicle A poorly bled cooling system is less effective at cooling and the engine can overheat B00897 01 Pour in coolant until it emerges without bubbles at the vent hole and then mount and tighten the bleeder screw immediately Alternative 1 Coolant p 211 Alternative 2 Coolant mixed ready to use p 211 Fill t...

Page 165: ...ntilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and run it until it reaches operating temperature Six bars of the temperature display light up B01380 01 Stop the engine and allow it to cool down When the engine is cool check the coolant level in the radiator and if necessary add coolant Check the coolant level in the...

Page 166: ...specifications Adjust the play in the throttle cable x p 165 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and let it run idle Move the handl...

Page 167: ...n connector 100554 10 Plug in connector 1 is located under the seat close to where the top of the shock absorber is attached By disconnecting the plug in connector the ignition curve for fuel with an octane rating below 95 ROZ 95 RON 95 PON 91 is activated While the engine will have a slightly lower power output this setting prevents engine damage by hindering spark knocking due to poor fuel quali...

Page 168: ...ng below 95 ROZ 95 RON 95 PON 91 for no more than one tank full The ignition curve must be adjusted to low octane fuel Disconnect plug in connector 1 Figure 100554 10 p 165 Plug in connector disconnected Fuel with an octane rating of 80 to 94 RON can be used for one tank full p 165 Activate the ignition curve for fuel with an octane rating of 95 or higher ROZ 95 RON 95 PON 91 Connect plug in conne...

Page 169: ...ngine in an enclosed space without an effective exhaust extraction system Start the engine and run it until it reaches operating temperature Six bars of the temperature display light up B01381 10 Main work Switch off the engine Unscrew oil dipstick 1 wipe it off with a cloth and screw it back in all the way Unscrew the oil dipstick and read off the engine oil level The engine oil level must be bet...

Page 170: ...oil screens x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regula...

Page 171: ... p 90 Remove the seat p 93 Remove the storage compartment and hang it to one side x p 96 Remove the left fuel tank x p 97 100624 10 Main work Place a suitable container under the engine Remove the oil drain plug 1 with the magnet and seal ring Fully drain the engine oil out of the engine Remove screws 2 and cover 3 Pull oil screen out of the engine case with pliers B01383 10 Remove screw 4 on the ...

Page 172: ...il line 9 to one side 100627 10 Pull oil screen bk out of the oil tank Remove the oil filter x p 172 Clean all oil screens and oil drain plugs with a magnet Clean all sealing areas 100628 10 Check seal ring bl of the oil screen for damage and correct seating Insert oil screen bk into the oil tank Position the oil line Mount and tighten the screws Guideline Remaining chassis screws M6 10 Nm 7 4 lbf...

Page 173: ...Slide oil screen bm into the engine case with the TOP marking facing up Check the form ring in cover 3 for damage and correct seating Position cover 3 Mount and tighten the screws Guideline Remaining engine screws M6 10 Nm 7 4 lbf ft B01383 10 Position bracket 6 Mount and tighten screws 5 Guideline Remaining chassis screws M8 25 Nm 18 4 lbf ft Mount and tighten screw 4 on the right fuel tank Guide...

Page 174: ... of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Condition The underride guard has been removed Preparatory work Place a suitable container under the engine 100632 10 Main work Remove screws 1 Take off oil filter ...

Page 175: ... the parts and sealing surface 17 5 Installing the oil filter x 100631 10 Insert oil filter 1 Lubricate the O ring of the oil filter cover Mount the oil filter cover 2 Mount and tighten the screws Guideline Remaining engine screws M5 6 Nm 4 4 lbf ft 17 6 Filling up with engine oil x Info Too little engine oil or poor quality engine oil results in premature wear to the engine ...

Page 176: ...perature 0 C 32 F Engine oil SAE 5W 40 p 212 Replace the oil dipstick Raise the vehicle using the center stand p 86 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction sys...

Page 177: ...emperature 0 C 32 F Engine oil SAE 5W 40 p 212 Replace the oil dipstick 17 7 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the engine The engine oil level must be corrected when the engine is warm B01381 10 Remove oil dipstick 1 and add engine oil to the MAX marking Condition External temperature 0 C 32 F Engine oil SAE 10W 50 p 212 Condition ...

Page 178: ...17 SERVICE WORK ON THE ENGINE 176 Info For optimal performance of the engine oil do not mix different types of engine oil We recommend changing the engine oil if necessary Replace the oil dipstick ...

Page 179: ...tions or destroy these parts Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info If you clean the motorcycle regularly its value and appearance will be maintained over a long period Avoid direct sunshine on the motorcycle during cleaning 401061 01 Close off t...

Page 180: ...t or dirty brake sys tem Clean or dry a dirty or wet brake system by riding and braking gently After cleaning ride the vehicle a short distance until the engine warms up Info The heat produced causes water at inaccessible locations in the engine and on the brake system to evaporate Push back the protection caps of the handlebar controls to allow any water that has penetrated to evaporate After the...

Page 181: ...efore take precautions against aggressive road salt If the vehicle was operated in road salt clean it with cold water after riding Warm water would enhance the corrosive effects of salt 401060 01 Clean the motorcycle p 177 Clean the brakes Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts...

Page 182: ...18 CLEANING CARE 180 Info To prevent serious reduction of the braking efficiency make sure no anti corrosion substance gets on to the brake discs Clean the chain p 100 ...

Page 183: ...vice add fuel additive Fuel additive p 215 Ride the motorcycle until the low fuel warning lamp lights up and the display changes to TRIP F so that you can fill up with fresh fuel when you take the motorcycle back into service Clean the motorcycle p 177 Change the engine oil and filter clean the oil screens x p 168 Check the antifreeze and coolant level p 155 Check the tire air pressure p 129 Remov...

Page 184: ...ort time only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 19 2 Preparing for use after storage 401059 01 Raise the vehicle off of the center stand p 87 Recharge the battery x p 134 Install the battery x p 133 Set the clock p 42 Refuel p 72 Perform checks and maintenance measures when preparing for use p ...

Page 185: ... x Malfunction in CAN bus communica tion Check the CAN bus communication x Combination instrument defective Check the combination instrument x Control unit for electric start lock defective Check the control unit of the electric start lock x Engine turns only if the clutch lever is drawn The vehicle is in gear Shift the transmission to neutral Defect in safety start system Check the safety start s...

Page 186: ... Fill bleed the cooling system x p 161 Buckled or damaged radiator hose Change the radiator hose x Fuse FAN blown Change the fuses in the fuse box p 138 Thermostat defective Check the thermostat x Defect in radiator fan system Check the radiator fan system x Air in cooling system Fill bleed the cooling system x p 161 FI warning lamp MIL lights up flashes Defect in fuel injection system Read out th...

Page 187: ...the fuses in the fuse box p 138 Battery discharged Ignition not switched off when vehicle was parked Recharge the battery x p 134 Battery is not charged by alternator Check the charging voltage x Combination instrument shows nothing in the display Fuse ACC1 CLOCK blown Change the fuses in the fuse box p 138 Speedometer in combination instru ment not functioning Wiring harness of wheel revolution c...

Page 188: ...CU antenna Blink code of immobilizer indica tor lamp 14 Immobilizer indicator lamp flashes 1x short 1 second pause 4x short Error level condition Malfunction in transponder of black ignition key Blink code of immobilizer indica tor lamp 15 Immobilizer indicator lamp flashes 1x short 1 second pause 5x short Error level condition Black ignition key inactive Blink code of immobilizer indica tor lamp ...

Page 189: ...r indicator lamp flashes 3x short 1 second pause 1x short Error level condition Malfunction encryption request from EFI control unit to ICU Blink code of immobilizer indica tor lamp 32 Immobilizer indicator lamp flashes 3x short 1 second pause 2x short Error level condition Malfunction in CAN bus communication Blink code of immobilizer indica tor lamp 60 Immobilizer indicator lamp flashes 6x short...

Page 190: ...mp MIL flashes 7x short Error level condition Throttle position sensor circuit B input signal too low Throttle position sensor circuit B input signal too high Blink code of FI warning lamp MIL 09 FI warning lamp MIL flashes 9x short Error level condition Manifold absolute pressure sensor cylinder 1 input signal too low Manifold absolute pressure sensor cylinder 1 input signal too high Blink code o...

Page 191: ...ow Intake air temperature sensor input signal too high Blink code of FI warning lamp MIL 14 FI warning lamp MIL flashes 1x long 4x short Error level condition Ambient air pressure sensor input signal too low Ambient air pressure sensor input signal too high Blink code of FI warning lamp MIL 15 FI warning lamp MIL flashes 1x long 5x short Error level condition Rollover sensor input signal too low R...

Page 192: ...rt Error level condition System voltage circuit fault Blink code of FI warning lamp MIL 25 FI warning lamp MIL flashes 2x long 5x short Error level condition Side stand circuit fault Blink code of FI warning lamp MIL 33 FI warning lamp MIL flashes 3x long 3x short Error level condition Injector cylinder 1 circuit fault Blink code of FI warning lamp MIL 34 FI warning lamp MIL flashes 3x long 4x sho...

Page 193: ...ror level condition Fuel pump control interruption short circuit to ground Fuel pump control input signal too high Blink code of FI warning lamp MIL 45 FI warning lamp MIL flashes 4x long 5x short Error level condition Heating lambda sensor cylinder 1 sensor 1 interruption short circuit to ground Heating lambda sensor cylinder 1 sensor 1 input signal too high Blink code of FI warning lamp MIL 46 F...

Page 194: ...FI warning lamp MIL flashes 5x long 3x short Error level condition Fuel evaporation valve short circuit to ground or open circuit Fuel evaporation valve input signal too high Blink code of FI warning lamp MIL 54 FI warning lamp MIL flashes 5x long 4x short Error level condition Secondary air valve interruption short circuit to ground Secondary air valve input signal too high Blink code of FI warni...

Page 195: ... Manifold absolute pressure sensor cylinder 2 connection leaks Blink code of FI warning lamp MIL 81 FI warning lamp MIL flashes 8x long 1x short Error level condition Immobilizer control unit circuit fault Blink code of FI warning lamp MIL 91 FI warning lamp MIL flashes 9x long 1x short Error level condition CAN bus communication error ...

Page 196: ...ke 38 mm 1 5 in Valve clearance Exhaust at 20 C 68 F 0 25 0 30 mm 0 0098 0 0118 in Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Crankshaft bearing Sleeve bearing Conrod bearing Sleeve bearing Piston Forged light alloy Piston ring 1 L ring 1 tapered compression piston ring 1 oil scraper ring Engine lubrication Dry sump lubrication system with two rotor pumps Primary transmission 35 67 Clutch M...

Page 197: ...t circulation of coolant by water pump Cold start device Electric starter 23 2 Engine tightening torques Hose clip intake flange M4 1 5 Nm 1 11 lbf ft Screw oil spray tube M4 6 Nm 4 4 lbf ft Loctite 243 Remaining engine screws M5 6 Nm 4 4 lbf ft Screw bearing retainer M5 6 Nm 4 4 lbf ft Loctite 243 Screw connecting angle on valve cover M5 3 Nm 2 2 lbf ft Loctite 243 Screw gear sensor M5 3 Nm 2 2 l...

Page 198: ...243 Screw freewheel hub M6 13 Nm 9 6 lbf ft Loctite 648 Screw oil pump housing M6 10 Nm 7 4 lbf ft Loctite 243 Screw pulse generator M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift lever M6 10 Nm 7 4 lbf ft Loctite 243 Screw starter motor M6 10 Nm 7 4 lbf ft Screw stator M6 10 Nm 7 4 lbf ft Loctite 243 Screw valve cover M6 10 Nm 7 4 lbf ft Scre...

Page 199: ...bf ft Step 2 34 Nm 25 1 lbf ft Only applies when using Box wrench attachment 13 mm 60029081000 Lubricated with engine oil Nut cylinder head on timing chain shaft M10 Step 1 25 Nm 18 4 lbf ft Step 2 38 Nm 28 lbf ft Lubricated with engine oil Plug clutch lubrication M10 15 Nm 11 1 lbf ft Screw bearing bolt of timing gears M10 30 Nm 22 1 lbf ft Stud cylinder head in engine case M10 20 Nm 14 8 lbf ft ...

Page 200: ...ft Loctite 243 Nut engine sprocket M20x1 5 100 Nm 73 8 lbf ft Loctite 243 Screw in fitting cooling system M20x1 5 10 Nm 7 4 lbf ft Loctite 577 Nut inner clutch hub M22x1 5 130 Nm 95 9 lbf ft Loctite 243 Oil drain plug with magnet M22x1 5 35 Nm 25 8 lbf ft Screw in alternator cover M24x1 5 8 Nm 5 9 lbf ft Nut primary gear M33LHx1 5 130 Nm 95 9 lbf ft Loctite 243 23 3 Capacities 23 3 1 Engine oil En...

Page 201: ...23 TECHNICAL DATA 199 23 3 3 Fuel Total fuel tank capacity approx 20 l 5 3 US gal Super unleaded ROZ 95 RON 95 PON 91 p 214 Fuel reserve approx 4 l 1 1 US gal ...

Page 202: ...ke with floating brake calipers and brake discs Rear Single disc brake with floating brake caliper and brake disc Brake system Two separate brake circuits without ABS antilock brake system 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 Brake disc wear limit Rear 4 5 mm 0 177 in Tire air pressure solo Front 2 4 bar 35 psi Rear 2 6 bar 38 ...

Page 203: ...Wheelbase 1 570 mm 61 81 in Seat height unloaded 860 mm 33 86 in Ground clearance unloaded 261 mm 10 28 in Weight without fuel approx 207 kg 456 lb Maximum permissible front axle load 200 kg 441 lb Maximum permissible rear axle load 250 kg 551 lb Maximum permissible total weight 430 kg 948 lb ...

Page 204: ...09125 25 A Fuse 58011109130 30 A Fuse 58011109140 40 A Low beam high beam H4 socket P43t 12 V 60 55 W Parking light W5W socket W2 1x9 5d 12 V 5 W Instrument lights and indicator lamps LED Turn signal RY10W socket BAU15s 12 V 10 W Tail light W5W socket W2 1x9 5d 12 V 5 W Brake light P21W socket BA15s 12 V 21 W License plate lamp W5W socket W2 1x9 5d 12 V 5 W ...

Page 205: ...ES 203 Front tires Rear tires 90 90 21 M C 54R TT Dunlop Rally Raid D 908 F RR 140 80 18 M C 70R TT Dunlop Rally Raid D 908 RR Additional information is available in the Service section under http www ktm com ...

Page 206: ...mfort 23 clicks Standard 18 clicks Sport 13 clicks Full payload 13 clicks Spring preload Preload Adjuster Comfort 5 turns Standard 5 turns Sport 8 turns Full payload 7 turns Spring length with preload spacer s 468 mm 18 43 in Spring rate Soft 4 6 N mm 26 3 lb in Medium standard 4 8 N mm 27 4 lb in Hard 5 0 N mm 28 6 lb in Fork length 880 mm 34 65 in Air chamber length 100 30 20 mm 3 94 1 18 0 79 i...

Page 207: ...27 FORK 205 Fork oil per fork leg 655 ml 22 15 fl oz Fork oil SAE 5 p 213 ...

Page 208: ...ks Full payload 15 clicks Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload Preload Adjuster Comfort 4 turns Standard 4 turns Sport 8 turns Full payload 16 turns Spring rate Soft 140 N mm 799 lb in Medium standard 150 N mm 857 lb in ...

Page 209: ...28 SHOCK ABSORBER 207 Spring length 225 mm 8 86 in Gas pressure 10 bar 145 psi Static sag 25 mm 0 98 in Fitted length 372 mm 14 65 in Shock absorber oil p 213 SAE 2 5 ...

Page 210: ... on bottom triple clamp M6 8 Nm 5 9 lbf ft Loctite 243 Screw cable line guide at top triple clamp M6 8 Nm 5 9 lbf ft Loctite 243 Screw chain guide M6 6 Nm 4 4 lbf ft Loctite 243 Screw chain sliding guard M6 6 Nm 4 4 lbf ft Loctite 243 Screw exhaust pipe bracket M6 12 Nm 8 9 lbf ft Loctite 243 Screw foot brake cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw front brake disc M6 14 Nm 10 3 lbf ft Loct...

Page 211: ... 18 4 lbf ft Loctite 243 Screw fuel tank M8 15 Nm 11 1 lbf ft Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw ignition lock ratchet screw M8 Loctite 243 Screw rear footrest bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw spring holder on side stand bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw steering stem M8 20 Nm 14 8 lbf ft Screw top triple clamp M8 20 Nm 14 8 lbf ft Screw underride guard M8 ...

Page 212: ...l drain plug with magnet M12x1 5 25 Nm 18 4 lbf ft Screw bottom shock absorber M14x1 5 80 Nm 59 lbf ft Thread greased Screw top shock absorber M14x1 5 80 Nm 59 lbf ft Thread greased Nut socket M18x1 4 Nm 3 lbf ft Lambda sensor M18x1 5 45 Nm 33 2 lbf ft Nut swingarm pivot M19x1 5 130 Nm 95 9 lbf ft Thread greased Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Nut rear wheel spindle M25x1 5 90 Nm ...

Page 213: ...ex products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant also in countries with high temperatures Use of low quality antifreeze can lead to corrosion and foaming KTM recommends Motorex products Mixture ratio Antifreeze protection 25 45 C 13 49 F 50 corrosion inhibitor antifreeze 50 distilled water Coolant mixed ready to u...

Page 214: ...orresponding properties KTM recommends Motorex products Fully synthetic engine oil Supplier Motorex Power Synt 4T Engine oil SAE 5W 40 According to JASO T903 MA p 218 SAE p 218 SAE 5W 40 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties KTM recommends Motorex products Synthetic engine oil Suppli...

Page 215: ...ulic fluid 15 According to ISO VG 15 Guideline Use only hydraulic oil that complies with the specified standard see specifications on the container and that possesses the corre sponding properties KTM recommends Motorex products Supplier Motorex Hydraulic Fluid 75 Shock absorber oil SAE 2 5 50180342S1 According to SAE p 218 SAE 2 5 Guideline Use only oils that comply with the specified standards s...

Page 216: ... 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 ...

Page 217: ...n lube for road use Guideline KTM recommends Motorex products Supplier Motorex Chainlube Road Cleaning and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Supplier Motorex Protect Shine Fuel additive Guideline KTM recommends Motorex products Supplier Motorex Fuel Stabilizer ...

Page 218: ... grease Guideline KTM recommends Motorex products Supplier Motorex Bike Grease 2000 Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean Polish ...

Page 219: ...31 AUXILIARY SUBSTANCES 217 Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Synthetic ...

Page 220: ...rvice intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Stan dard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils...

Page 221: ...linings front brake checking 115 rear brake checking 119 Brakes 68 Braking 68 C Capacity coolant 198 engine oil 174 198 fuel 73 199 Center stand 57 Chain checking 105 checking for dirt 100 cleaning 100 Chain tension adjusting 103 checking 102 Chassis number 28 Clutch fluid level checking rectifying 108 Clutch lever 32 adjusting 108 Combination instrument clock setting 42 coolant temperature indica...

Page 222: ...eding 161 Crash bar installing 95 removing 94 Customer service 23 D Display 40 E Electric starter button 36 Emergency OFF switch 35 Engine running in 59 Engine number 30 Engine oil adding 175 changing 168 draining 168 refilling 173 Engine oil level checking 167 Engine sprocket checking 105 Environment 21 F Figures 23 Filler caps closing 50 opening 48 Foot brake lever 56 checking free travel 116 Fo...

Page 223: ... 47 Headlight headlight range adjusting 148 Headlight adjustment checking 148 Headlight bulb changing 142 Headlight flasher switch 34 Headlight mask with headlight installing 141 removing 140 Horn button 33 I Ignition curve adjusting to fuel quality 166 plug in connector 165 Ignition key activating deactivating 149 Ignition lock 36 Immobilizer 37 Indicator lamps 39 Intended use 9 K Key number 29 L...

Page 224: ...es when preparing for use 62 information on first use 58 Protective clothing 20 R Radiator guard installing 92 removing 91 Rear hub rubber dampers checking 126 Rear sprocket checking 105 Rear wheel installing 125 removing 123 Refueling fuel 72 Riding 65 starting off 65 S Safe operation 19 Seat mounting 93 removing 93 Seat lock 53 Service 22 Service schedule 75 77 Shift lever 55 Shifting 65 Shock a...

Page 225: ...closing 52 installing 96 locking 51 opening 51 removing and hanging to one side 96 unlocking 50 T Tachometer 38 Tail light bulb changing 145 Technical data capacities 198 chassis 200 201 chassis tightening torques 208 210 electrical system 202 engine 194 engine tightening torques 195 fork 204 205 shock absorber 206 207 tires 203 Throttle grip 33 Tire air pressure checking 129 Tire condition checki...

Page 226: ...nstalling 109 removing 109 Use definition 9 V Vehicle loading 60 raising off of center stand 87 raising using the center stand 86 View of vehicle front left 24 rear right 26 W Warning of slippery roads 46 Warranty 22 Winter operation checks and maintenance steps 179 Work rules 20 ...

Page 227: ... 3211908en 3211908en 12 2012 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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KTM 990 Adventure Baja, Owner'S Manual

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