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KTM 990 SUPERMOTO R AUS/UK, Owner'S Manual

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KTM 990 SUPERMOTO R AUS/UK Owner'S Manual Download Page 89

11

SERVICE WORK ON THE CHASSIS

87

11.16

Adjusting the chain tension

Warning

Danger of accidents

 

Danger caused by incorrect chain tension.

–

If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, 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.

Preparatory work

–

Lean the motorcycle on the side stand.

–

Check the chain tension. (

p. 86)

Summary of Contents for 990 SUPERMOTO R AUS/UK

Page 1: ...OWNER S MANUAL 2013 990 Supermoto T EU 990 Supermoto T AUS UK 990 Supermoto T FR Art no 3211957en...

Page 2: ......

Page 3: ...y All specifications are non binding KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications prices colors forms materials services designs equipment etc wi...

Page 4: ...ccording 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 T V Management Service KTM S...

Page 5: ...Type label 20 5 3 Key number 21 5 4 Engine number 21 5 5 Fork part number 22 5 6 Shock absorber part number 22 6 CONTROLS 23 6 1 Clutch lever 23 6 2 Hand brake lever 23 6 3 Throttle grip 24 6 4 Horn b...

Page 6: ...Refueling 60 9 SERVICE SCHEDULE 62 9 1 Service schedule 62 10 TUNING THE CHASSIS 65 10 1 Fork shock absorber 65 10 2 Adjusting the compression damping of the fork 65 10 3 Adjusting the rebound damping...

Page 7: ...101 12 10 Checking the rear brake fluid level 101 12 11 Adding rear brake fluid x 102 12 12 Checking the rear brake linings 104 13 WHEELS TIRES 106 13 1 Removing the front wheel x 106 13 2 Installing...

Page 8: ...l and filter cleaning the oil screens x 163 17 3 Draining the engine oil and filter cleaning the oil screens x 163 17 4 Filling up with engine oil x 168 17 5 Adding engine oil 169 18 CLEANING CARE 170...

Page 9: ...standing 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...

Page 10: ...he 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...

Page 11: ...n Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken 2 4 Tampering warning Tampering with the noise control system is prohibited Federal law p...

Page 12: ...ousness 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 War...

Page 13: ...s In some instances a thread locker e g Loctite is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them for damage and...

Page 14: ...hen will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it as...

Page 15: ...ge 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 fou...

Page 16: ...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 wi...

Page 17: ...15...

Page 18: ...4 VIEW OF VEHICLE 16 4 1 View of vehicle front left side example L00600 10...

Page 19: ...VEHICLE 17 1 Function buttons p 29 1 indicator lamps p 30 2 Clutch lever p 23 3 Handrails p 42 4 Level viewer engine oil 5 Shift lever p 44 6 Engine number p 21 7 Compression damping of the shock abso...

Page 20: ...4 VIEW OF VEHICLE 18 4 2 View of vehicle rear right side example L00601 10...

Page 21: ...rn button p 24 3 Filler cap 4 Emergency OFF switch p 26 4 Electric starter button p 27 5 Hand brake lever p 23 6 Fork rebound setting and spring preload setting 7 Passenger footrests p 43 8 Shock abso...

Page 22: ...5 SERIAL NUMBERS 20 5 1 Chassis number L00604 10 Chassis number 1 is embossed in the steering head at the right 5 2 Type label L00603 10 Type label 1 is located on the upper frame tube on the right...

Page 23: ...re 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 le...

Page 24: ...B00606 10 The fork part number 1 is stamped on the inner side of the fork stub 5 6 Shock absorber part number L00606 10 The shock absorber part number 1 is stamped on the top of the shock absorber abo...

Page 25: ...r 1 is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 6 2 Hand brake lever B00609 10 The hand brake lever 1 is fitted on the right side of the handleb...

Page 26: ...ottle grip 1 is fitted on the right side of the handlebar 6 4 Horn button B00656 12 The horn button 1 is fitted on the left side of the handlebar Possible states Horn button in basic position Horn but...

Page 27: ...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 B00685 10 The headlight flasher switch...

Page 28: ...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...

Page 29: ...triple 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...

Page 30: ...s 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 blac...

Page 31: ...r 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 The ABS can be switched off usi...

Page 32: ...ed The coolant temperature has reached a critical value The low fuel warning lamp lights up yellow The fuel level has reached the reserve mark The display switches to TRIP F The oil pressure warning l...

Page 33: ...up for one second as a function check 400881 01 LEnGth Following the display function check the LEnGth wheel circumference is shown for one sec ond Info 1870 mm corresponds to the circumference of the...

Page 34: ...s 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 accor...

Page 35: ...l 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 re...

Page 36: ...on 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 retain...

Page 37: ...IP 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...

Page 38: ...o TRIP F and starts to count from 0 0 regardless of the previous display mode Info The low fuel warning lamp lights up in parallel to the TRIP F display 6 12 14 Ambient temperature indicator 400893 13...

Page 39: ...isplay 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 w...

Page 40: ...warning flasher B00658 10 The hazard warning flasher switch 1 is fitted next to the combination instrument on the left The hazard warning flasher is used to indicate emergency situations Info The haza...

Page 41: ...ul 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 refuelin...

Page 42: ...he ignition key Note Danger of damage Ignition 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 counte...

Page 43: ...6 17 Seat lock 600922 10 Seat lock 1 is located at the rear under the tail light It can be locked with the ignition key 6 18 Tool set B00612 10 The tool set 1 is located in the storage compartment un...

Page 44: ...lock L00609 10 Warning Danger of accidents Impairment of ride behavior and vehicle operation if a helmet or helmet lock is attached to the vehicle Do not use the helmet lock for holding a helmet or ot...

Page 45: ...may not be loaded with more than the specified weight Maximum permissible load of luggage rack plate 8 kg 18 lb Info Follow the instructions provided by the luggage manufacturer 6 22 Passenger footre...

Page 46: ...4 6 23 Shift lever L00610 11 Shift lever 1 is mounted on the left side of the engine L00610 10 The gear positions can be seen in the photograph The neutral or idle position N is between the first and...

Page 47: ...e vehicle The side stand is used to park the motorcycle Info The side stand must be folded up during motorcycle use The side stand is coupled with the safety starting system see the riding instruc tio...

Page 48: ...ferent 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 accide...

Page 49: ...ger trip Try also to ride as slowly as possible to get a better feeling for the motorcycle Hold the handlebar firmly with both hands and keep your feet on the footrests when riding Run the engine in p...

Page 50: ...ses note the manufacturer s specifications concerning the maximum payload Warning Danger of accidents Poor visibility for other road users due to slipped baggage If the tail light is covered you are l...

Page 51: ...r of the vehicle and ensure even weight distri bution between the front and rear wheels Do not exceed the maximum permissible total weight and the axle loads Guideline Maximum permissible total weight...

Page 52: ...evel p 101 Check the front brake linings p 98 Check the rear brake linings p 104 Check that the brake system is functioning properly Check the coolant level in the compensating tank p 152 Check the ch...

Page 53: ...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 of the engine Always warm up the engine at...

Page 54: ...cle is equipped with a safety starting system You can only start the engine if the transmission is in neutral or if the clutch is pulled when a gear is engaged If the side stand is folded out and you...

Page 55: ...ng 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...

Page 56: ...e tires have been run in Warning Danger of accidents Unstable handling characteristics Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational a...

Page 57: ...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 i...

Page 58: ...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 pres...

Page 59: ...Warning Danger of accidents Locking of the wheels due to braking action of the engine Pull the clutch during emergency braking full brake application and when braking on a slippery surface When braki...

Page 60: ...s exhaust system radiator engine shock absorber and the brake system Allow these components to cool down before starting work on them Note Danger of damage The parked vehicle may roll away or fall ove...

Page 61: ...e stand to the front with your foot as far as it will go and lean the vehicle onto it Lock the steering by turning the handlebar fully to the left pressing down the ignition key to the OFF position an...

Page 62: ...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 v...

Page 63: ...n the filler cap p 39 Fill the fuel tank with fuel no higher than level A Guideline Distance A 35 mm 1 38 in Total fuel tank capacity approx 19 l 5 US gal Super unleaded ROZ 95 RON 95 PON 91 p 204 Clo...

Page 64: ...rear brake linings p 104 Check the rear brake disc p 101 Check that brake lines are undamaged and free of leaks Check the rear brake fluid level p 101 Check the free travel of the foot brake lever p 9...

Page 65: ...ss 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 f...

Page 66: ...oadworthiness and take a test ride Read out the fault memory after a test ride using the KTM diagnostics tool x Make the service entries in the KTM DEALER NET and service record x K10N Once after 1 00...

Page 67: ...turn the adjusting screws against the stop and take the last perceptible click as the end position These adjustments should be understood as a guideline and should always be the basis of your own pers...

Page 68: ...o the fork type Guideline Compression damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce dampin...

Page 69: ...eline Rebound damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 10 4 Adjusting the spr...

Page 70: ...ns according to the fork type Guideline Spring preload Preload Adjuster Comfort 5 turns Standard 5 turns Sport 3 turns Full payload 3 turns Info Turn clockwise to increase preload turn counterclockwis...

Page 71: ...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...

Page 72: ...licks 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 Cau...

Page 73: ...mping 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...

Page 74: ...absorber Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle s ride behavior Following modifications ride slowly at first to get the feel of the new r...

Page 75: ...the side Turn the Preload Adjuster counterclockwise all the way 6 mm 0 24 in Hexagon socket wrench tool set Turn it clockwise by the number of turns corresponding to the shock absorber type and use G...

Page 76: ...HASSIS 74 C00136 10 Position the brake line guide and brake line Info Watch out for the holding lug of the brake line guide Mount and tighten screw 1 Guideline Screw brake line holder EJOT PT K60x20 2...

Page 77: ...stand Adapter 61029055120 Rear wheel stand 61029055400 Stand the motorcycle upright align the wheel stand with the swingarm and the adapters and lift the motorcycle 11 2 Taking the motorcycle off of...

Page 78: ...Main work Move the handlebar to the straight ahead position Align the front wheel stand with the fork legs using the adapters Front wheel stand 61029055300 Info Always raise the rear of the motorcycle...

Page 79: ...iefly Any excess pressure escapes from the interior of the fork Mount and tighten the bleeder screws Info Carry out this operation on both fork legs 11 6 Removing the seat 600922 10 Insert the ignitio...

Page 80: ...neously push it forward Both lugs 2 must hook into the frame and locking bolt 3 must be inserted into the lock housing The seat engages with an audible click Finally check that the seat is correctly m...

Page 81: ...h the fuel tank back 11 9 Positioning the fuel tank Main work Carefully push the fuel tank forward The fuel tank fixations must engage in the recesses C00368 10 Install and tighten screw 1 with the be...

Page 82: ...rk Install the mask spoiler p 83 Mount the seat p 78 11 10 Mounting the helmet lock on the vehicle Warning Danger of accidents Impairment of ride behavior and vehicle operation if a helmet or helmet l...

Page 83: ...ool set with one loop on the lug 1 Steel cable 60012015000 Guide the steel cable through the helmet opening Then position the free loop of the steel cable on the lug Position the helmet carefully on t...

Page 84: ...11 SERVICE WORK ON THE CHASSIS 82 C00366 10 Remove screws 2 Remove the mask spoiler C00365 11 Remove screws 3 Remove the inside trim of the mask spoiler Repeat the operation on the opposite side...

Page 85: ...VICE WORK ON THE CHASSIS 83 11 12 Installing the mask spoiler C00365 10 Position the inside trim of the mask spoiler Mount and tighten screws 1 C00367 11 Position the mask spoiler Mount and tighten sc...

Page 86: ...osite side 11 13 Checking the chain for dirt 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 84 11 14 Cleaning the chain Warning Danger of accidents...

Page 87: ...tal 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 c...

Page 88: ...and 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 Preparatory work Lean...

Page 89: ...rings 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 t...

Page 90: ...eference 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 n...

Page 91: ...ar sprocket engine sprocket and chain guide 100132 10 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...

Page 92: ...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...

Page 93: ...en the chain sliding guard Guideline Screw chain sliding guard M5 5 Nm 3 7 lbf ft Screw chain sliding guard M6 6 Nm 4 4 lbf ft Loctite 243 C00364 10 Check the chain sliding piece for wear If the drill...

Page 94: ...t is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding B00608 12 Adjust the basic setting of the clutch lever to your hand size by turni...

Page 95: ...al position Remove screws 1 Remove cover 2 with membrane 3 Check the fluid level Fluid level below container rim 4 mm 0 16 in If the coolant level does not meet specifications Correct the fluid level...

Page 96: ...work and repairs must be performed properly Your authorized KTM workshop will be glad to help The ABS is a safety system that prevents locking of the wheels when the vehicle is traveling straight ahea...

Page 97: ...such as during wheelies or when the rear wheel spins This switches off the ABS To reactivate the ABS stop the vehicle and switch off the ignition ABS is reactivated when the vehicle is switched back...

Page 98: ...discs exhibit damage cracking or deformation Change the brake discs x 12 4 Checking the front brake fluid level Warning Danger of accidents Failure of the brake system If the brake fluid level falls b...

Page 99: ...rake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact...

Page 100: ...container B00629 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover 1 with membrane 2 Add brake fluid to the MAX mark Brake fluid DOT 4 DOT...

Page 101: ...imum thick ness A Minimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified Change the front brake linings x Check all brake linings on both brake calipers for damage and cracki...

Page 102: ...asic position of the foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake ca...

Page 103: ...e disc Brake disc wear limit Rear 4 5 mm 0 177 in If the brake disc thickness is less than the specified value Change the brake disc x Check the brake disc for damage cracking and deformation If damag...

Page 104: ...rear brake fluid x Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Chec...

Page 105: ...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...

Page 106: ...rning 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 Reduc...

Page 107: ...or 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 damage or wea...

Page 108: ...ing of the brake calipers on the brake disc Pull the brake calipers carefully back from the brake discs and hang them to one side Info Do not pull the hand brake lever when the brake calipers are remo...

Page 109: ...10 Check the wheel bearing for damage and wear If the wheel bearing is broken or worn Replace the wheel bearing x Clean grease and mount the left and right spacers and the shaft seal rings Long life g...

Page 110: ...Mount screws 5 on both brake calipers but do not tighten yet Operate the hand brake lever repeatedly until the brake lining presses up against the brake disc and there is a pressure point Fix the hand...

Page 111: ...nt brake and compress the fork powerfully a few times The fork legs straighten Tighten screws 6 Guideline Screw fork stub M8 15 Nm 11 1 lbf ft 13 3 Removing the rear wheel x Preparatory work Raise the...

Page 112: ...with the adjusting screw B00135 01 Push the rear wheel forward as far as possible and take the chain off the rear sprocket Withdraw the wheel spindle Pull the rear wheel backward until the brake cali...

Page 113: ...with brake cleaner when necessary Warning Danger of accidents No braking effect when operating the rear brake After installing the rear wheel always operate the foot brake until the pressure point is...

Page 114: ...the chain adjusters are in contact with the adjust ing screws and tighten the nut Guideline In order for the rear wheel to be correctly aligned the markings on the left and right chain adjusters must...

Page 115: ...orcycle with the rear wheel stand p 75 Remove the rear wheel x p 109 B00636 01 Main work Remove the rear sprocket carrier Check the rubber dampers of the rear hub for damage and wear If the rubber dam...

Page 116: ...s Uncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Warning Danger...

Page 117: ...ires 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 las...

Page 118: ...nt 2 4 bar 35 psi Rear 2 4 bar 35 psi Tire air pressure with passenger full payload Front 2 4 bar 35 psi Rear 2 6 bar 38 psi If the tire pressure does not meet specifications Correct the tire pressure...

Page 119: ...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 Ca...

Page 120: ...7 10 Main work Disconnect negative minus cable 1 of the battery B00638 10 Remove positive terminal cover 2 Disconnect the positive plus cable 3 of the battery Detach rubber band 4 Pull the battery up...

Page 121: ...tery holder Info The terminals of the battery must face in the direction of travel Attach rubber band 1 Reconnect the positive plus 2 cable of the battery Position positive terminal cover 3 B00637 11...

Page 122: ...amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Warning Environmental hazard The battery contains elements that are harmful to the e...

Page 123: ...hrough 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 discharge...

Page 124: ...emove lid 1 Charge the battery to no more than 10 of the capacity specified on battery housing 2 Switch off the charger after charging Reconnect the battery Guideline The charge current charge voltage...

Page 125: ...he seat p 77 B00640 10 Main work Remove protection covers 1 Remove the faulty main fuse 2 Info A defective fuse can be identified by the burned out fuse wire A A reserve fuse 3 is located in the start...

Page 126: ...ABS are located under the seat These fuses protect the return pump and the hydraulic unit of the ABS The third fuse which protects the ABS control unit is located in the fuse box Preparatory work Swi...

Page 127: ...t p 78 14 6 Changing the fuses of individual power consumers Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never b...

Page 128: ...license plate lamp Fuse 3 10 A horn brake light turn signal Fuse 4 10 A radiator fan Fuse 5 10 A ignition EFI control unit immobilizer Fuse 6 10 A combination instrument auxiliary equipment permanent...

Page 129: ...t p 78 14 7 Changing the headlight bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free...

Page 130: ...retaining clamps 3 Remove headlight bulb 4 Position the new headlight bulb in the headlight housing Low beam high beam H4 socket P43t p 195 Info Insert the headlight bulb so that the catches latch in...

Page 131: ...parking light bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mou...

Page 132: ...ight carefully out of the housing Remove the bulb Position a new light bulb in the socket Parking light W5W socket W2 1x9 5d p 195 Carefully position the socket with the bulb in the housing Mount the...

Page 133: ...ut 30 and pull it out of the socket Press the new bulb carefully into the socket and turn it clockwise until it stops Turn signal RY10W socket BAU15s p 195 Check the turn signal to make sure it is fun...

Page 134: ...14 ELECTRICAL SYSTEM 132 B00641 10 Main work Remove screws 1 Remove the grab handles C00355 10 Remove screws 2 on the left and right heat protectors Remove the heat protectors...

Page 135: ...14 ELECTRICAL SYSTEM 133 C00356 10 Remove screws 3 on the left and right rear side parts Remove screws 4 Remove the rear side parts B00644 10 Remove screws 5 Remove the rear top part...

Page 136: ...new bulb carefully into the socket and turn it clockwise until it stops Brake light PR21W socket BAW15s p 195 Insert the bulb socket into the tail light and turn clockwise until it stops Check that t...

Page 137: ...screw con nection 3 3 Nm 2 43 lbf ft Subsequent screw connection 2 Nm 1 5 lbf ft Mount and tighten screws 4 Guideline Remaining chassis screws M5 5 Nm 3 7 lbf ft Remaining frame bolts EJOT PT K50x12 T...

Page 138: ...8 20 Nm 14 8 lbf ft Finishing work Mount the seat p 78 14 11 Changing the tail light bulbs Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposite...

Page 139: ...14 ELECTRICAL SYSTEM 137 B00641 10 Main work Remove screws 1 Remove the grab handles C00355 10 Remove screws 2 on the left and right heat protectors Remove the heat protectors...

Page 140: ...14 ELECTRICAL SYSTEM 138 C00356 10 Remove screws 3 on the left and right rear side parts Remove screws 4 Remove the rear side parts B00644 10 Remove screws 5 Remove the rear top part...

Page 141: ...ight WR5W socket W2 1x9 5d p 195 Carefully position the sockets with the bulbs into the holder in the tail light Check that the tail light bulbs are functioning properly B00644 10 Position the rear to...

Page 142: ...screw con nection 3 3 Nm 2 43 lbf ft Subsequent screw connection 2 Nm 1 5 lbf ft Mount and tighten screws 4 Guideline Remaining chassis screws M5 5 Nm 3 7 lbf ft Remaining frame bolts EJOT PT K50x12 T...

Page 143: ...tion the grab handles Mount and tighten screws 1 Guideline Screw handrail M8 20 Nm 14 8 lbf ft Finishing work Mount the seat p 78 14 12 Changing the license plate lamp 700602 01 Main work Remove screw...

Page 144: ...the bulb Position a new light bulb in the holder License plate lamp W5W socket W2 1x9 5d p 195 Carefully position the socket with the bulb into the holder 700602 01 Position the cover Mount and tighte...

Page 145: ...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 l...

Page 146: ...ignition key Info The orange programming key must only be used for activating and deactivating If a black ignition key is lost or replaced the black ignition keys must be individually activated deact...

Page 147: ...ts up 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...

Page 148: ...n key Press the emergency OFF switch into the position B00652 10 Insert the orange programming key in the ignition lock Switch on the ignition by turning the orange programming key to the ON position...

Page 149: ...up 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 t...

Page 150: ...mber 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...

Page 151: ...wer 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 fall...

Page 152: ...e is cold Preparatory work Stand the motorcycle upright on a horizontal surface Remove the seat p 77 Remove the mask spoiler p 81 Reset the fuel tank p 78 C00354 10 Main work Remove radiator cap 1 and...

Page 153: ...f the compensating tank C00353 10 Check the coolant level in the radiator The radiator must be completely filled If the coolant level does not meet specifications Correct the coolant level and determi...

Page 154: ...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...

Page 155: ...oling 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 poisono...

Page 156: ...Mount screw 3 with a new seal ring and tighten it Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft 15 5 Filling bleeding the cooling system x Warning Danger of poisoning Coolant is poisonous and a...

Page 157: ...mp cover are tightened Remove bleeder screw 1 0 0 A A 400677 10 Position the vehicle as shown and secure it against rolling Height difference A must be reached Guideline Height difference A 50 cm 19 7...

Page 158: ...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...

Page 159: ...pecifications Adjust the play in the throttle cable x p 158 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine alwa...

Page 160: ...for ease of movement 16 3 Plug in connection ignition timing map 101170 01 The plug in connection is located under the seat in front of the tail light By disconnecting the plug in connector the igniti...

Page 161: ...with an octane rating 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 Plug in connection disconnected...

Page 162: ...ne the distance A between the upper edge of your boot and the shift lever Distance between shift lever and upper edge of boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust...

Page 163: ...lever on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle components during the...

Page 164: ...exhaust extraction system Start the engine and run it until it reaches operating temperature Six bars of the temperature display light up B00683 11 Main work Switch off the engine Park the motorcycle...

Page 165: ...il 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 wit...

Page 166: ...ace 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 700610 10 Remove screws 2 and cover 3 700612 10 Pull oi...

Page 167: ...to one side 700615 10 Pull oil screen 8 out of the oil tank 700617 10 Remove screw connection 9 and move the oil line to one side Remove the screws Remove the oil filter cover bk with the O ring Pull...

Page 168: ...filter cover bk Mount and tighten the screws Guideline Remaining engine screws M5 6 Nm 4 4 lbf ft Position the oil line Mount and tighten screw connection 9 Guideline Nut oil line M16x1 5 25 Nm 18 4...

Page 169: ...n plug with magnet M12x1 5 25 Nm 18 4 lbf ft 700611 10 Mount oil drain plug 1 with the magnet and new seal ring and tighten Guideline Oil drain plug with magnet M22x1 5 35 Nm 25 8 lbf ft 700616 10 Sli...

Page 170: ...the top marking 2 Mount the plug 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 suffi...

Page 171: ...e The engine oil level must be corrected when the engine is warm B00683 10 Remove plug 1 and add engine oil to the top marking 2 Condition External temperature 0 C 32 F Engine oil SAE 10W 50 p 203 Con...

Page 172: ...ns 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 applicabl...

Page 173: ...duced braking efficiency due to a wet or dirty brake sys tem Clean or dry a dirty or wet brake system by riding and braking gently After cleaning ride the vehicle a short distance until the engine war...

Page 174: ...ted in road salt clean it with cold water after use Warm water would enhance the corrosive effects of salt 401060 01 Clean the motorcycle p 170 Clean the brake system Info After EVERY trip on salted r...

Page 175: ...18 CLEANING CARE 173 Clean the chain p 84...

Page 176: ...orcycle check all parts for function and wear If service repairs or replacements are necessary you should do this during the storage period less overload of the authorized KTM workshop In this way you...

Page 177: ...rcycle with the rear wheel stand p 75 Raise the motorcycle with the front wheel stand p 76 Cover the motorcycle with a tarp or cover that is permeable to air Info Do not use non porous materials since...

Page 178: ...motorcycle off of the front wheel stand p 76 Take the motorcycle off of the rear wheel stand p 75 Recharge the battery x p 120 Install the battery x p 119 Set the clock p 33 Refuel p 60 Perform checks...

Page 179: ...in CAN bus communica tion Read out the trouble code memory using the KTM diagnostics tool x Combination instrument defective Check the combination instrument x Control unit for electric start lock def...

Page 180: ...hermostat 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 154 FI warning lamp MIL lights up flash...

Page 181: ...dual power consumers p 125 Turn signal hazard warning flasher brake light and horn are not functional 1 or 3 fuse blown Change the fuses of individual power consumers p 125 Battery discharged Ignition...

Page 182: ...lfunction 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...

Page 183: ...r lamp flashes 3x short 1 second pause 1x short Error level condition Malfunction encryption query from EFI control unit to immobilizer control unit Blink code of immobilizer indica tor lamp 32 Immobi...

Page 184: ...lamp 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...

Page 185: ...w 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 t...

Page 186: ...short Error level condition Power supply 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 F...

Page 187: ...or 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 Erro...

Page 188: ...I 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 o...

Page 189: ...ing 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 sh...

Page 190: ...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...

Page 191: ...ump Idle speed 1 400 1 500 rpm Cold start device Electric starter 23 2 Engine tightening torques Screw damping plate clutch cover EJOT Altracs M6x10 10 Nm 7 4 lbf ft Loctite 243 Hose clip intake flang...

Page 192: ...ew 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...

Page 193: ...f 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...

Page 194: ...t 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 24...

Page 195: ...e Down 4860 ROMA PA Shock absorber WP Suspension 4618 BAVP DCC PA Suspension travel Front 160 mm 6 3 in Rear 180 mm 7 09 in Brake system Front Double disc brake with radially screwed four piston brake...

Page 196: ...1 505 15 mm 59 25 0 59 in Seat height unloaded 855 mm 33 66 in Ground clearance unloaded 195 mm 7 68 in Weight without fuel approx 198 kg 437 lb Maximum permissible front axle load 160 kg 353 lb Maxi...

Page 197: ...W Brake light PR21W socket BAW15s 12 V 21 W License plate lamp W5W socket W2 1x9 5d 12 V 5 W 23 6 Tires Front tires Rear tires 120 70 ZR 17 M C 58W TL Continental ContiSportAttack 180 55 ZR 17 M C 73W...

Page 198: ...dard 5 turns Sport 3 turns Full payload 3 turns Spring length with preload spacer s 384 mm 15 12 in Spring rate Medium standard 7 0 N mm 40 lb in Fork length 877 mm 34 53 in Air chamber length 100 20...

Page 199: ...ns 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 2 turns Standard 2 turns Sport 4...

Page 200: ...12 1 Nm 0 7 lbf ft Screw rear side part EJOT Altracs 50x16 Initial screw connection 3 3 Nm 2 43 lbf ft Subsequent screw connec tion 2 Nm 1 5 lbf ft Screw side stand switch M4 2 Nm 1 5 lbf ft Loctite 2...

Page 201: ...M6 3 3 Nm 2 43 lbf ft Screw splash protector M6 6 Nm 4 4 lbf ft Loctite 243 Screw spoiler M6 3 3 Nm 2 43 lbf ft Screw wheel speed sensor M6 6 Nm 4 4 lbf ft Loctite 243 Nut manifold on cylinder head M...

Page 202: ...45 Nm 33 2 lbf ft Remaining frame bolts M10 45 Nm 33 2 lbf ft Screw connection engine mounting bracket M10 45 Nm 33 2 lbf ft Screw handlebar support M10 20 Nm 14 8 lbf ft Screw side stand M10 35 Nm 2...

Page 203: ...bf ft Thread greased Screw top shock absorber M14x1 5 80 Nm 59 lbf ft Thread greased Nut oil line M16x1 5 25 Nm 18 4 lbf ft Nut swingarm pivot M19x1 5 130 Nm 95 9 lbf ft Thread greased Screw steering...

Page 204: ...x products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant also in countries with high temperatures Use of low quality antifre...

Page 205: ...rresponding 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 209 SAE p 209 SAE 5W 40 Guideline Use...

Page 206: ...l 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 Sho...

Page 207: ...aded 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...

Page 208: ...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 Su...

Page 209: ...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...

Page 210: ...25 AUXILIARY SUBSTANCES 208 Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Synthetic...

Page 211: ...vice 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 wit...

Page 212: ...brake adding 97 rear brake adding 102 Brake fluid level front brake checking 96 rear brake checking 101 Brake light bulb changing 131 Brake linings front brake checking 98 rear brake checking 104 Brak...

Page 213: ...F display 36 warning of slippery roads 37 Coolant draining 153 Coolant level checking 149 compensating tank checking 152 Cooling system 149 filling bleeding 154 Customer service 14 E Electric starter...

Page 214: ...rning flasher 38 Hazard warning flasher switch 38 Headlight headlight range adjusting 143 Headlight adjustment checking 143 Headlight bulb changing 127 Headlight flasher switch 25 Helmet lock 42 mount...

Page 215: ...b changing 129 Passenger footrests 43 Play in throttle cable adjusting 158 checking 157 Preparing for use after storage 176 checks and maintenance measures when preparing for use 50 information on fir...

Page 216: ...ping 58 Storage 174 T Tail light bulbs changing 136 Technical data capacities 192 chassis 193 chassis tightening torques 198 electrical system 194 engine 188 engine tightening torques 189 fork 195 sho...

Page 217: ...INDEX 215 Winter operation checks and maintenance measures 172 Work rules 11...

Page 218: ...3211957en 3211957en 12 2012 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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