KTM 990 Supermoto R Owner'S Manual Download

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OWNER'S MANUAL

2010

990 Supermoto R USA

990 Supermoto T USA

Art. no. 3211562en

Summary of Contents for 990 Supermoto R

Page 1: ...OWNER S MANUAL 2010 990 Supermoto R USA 990 Supermoto T USA Art no 3211562en ...

Page 2: ......

Page 3: ...o print However it is never possible to exclude small deviations arising from further development in design and construction 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 con...

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

Page 5: ...ument function buttons 41 Combination instrument tachometer 42 Combination instrument indicator lamps 42 Combination instrument display 43 Combination instrument speedometer 44 Setting kilometers or miles 44 Combination instrument time 45 Setting the clock 46 Combination instrument ODO display 46 Combination instrument setting resetting TRIP 1 47 Combination instrument setting resetting TRIP 2 47 ...

Page 6: ... absorber x 86 Checking the chain for dirt 88 Cleaning the chain 88 Checking the chain tension 90 Adjusting the chain tension 91 Checking the chain rear sprocket and engine sprocket 93 Checking the front brake discs 95 Checking the rear brake disc 96 Adjusting the basic position of the hand brake lever 97 Checking the free travel of the foot brake lever 97 Checking the front brake fluid level 98 A...

Page 7: ...ble 161 Adjusting the play in the throttle cable x 162 Checking the engine oil level 162 Changing the engine oil and filter cleaning the oil screens x 163 Draining the engine oil and filter cleaning the oil screens x 164 Filling up with engine oil x 168 Adding engine oil 170 Ignition curve plug in connector 171 Adjusting the ignition curve to the fuel quality 171 IMMOBILIZER BLINK CODE 173 ENGINE ...

Page 8: ...TABLE OF CONTENTS 6 STANDARDS 212 INDEX 213 ...

Page 9: ...tanding In the interest of your own safety have these jobs performed by an authorized KTM workshop There your motorcycle will be serviced opti mally by specially trained experts using the specialist tools required Identifies a page reference more information is provided on the specified page Formats used The typographical formats used in this document are explained below Specific name Identifies a...

Page 10: ...ddy or wet roads can lead to above average wear of components such as the transmission train or the brakes For this reason it may be necessary to service or replace worn parts before the limit specified in the ser vice schedule is reached Pay careful attention to the prescribed running in period and inspection and maintenance intervals Close adherence to these periods will significantly lengthen t...

Page 11: ...lve spring mounter 59029019000 During assembly non reusable parts e g self locking screws and nuts seals and seal rings O rings pins lock washers must be replaced by new parts If a thread lock e g Loctite is used for screw connections be sure to comply with the manufacturer s specific instructions on its usage Parts that you want to reuse following repairs and servicing should be cleaned and check...

Page 12: ...rful sport and we naturally hope that you can enjoy it to the full However it can also lead to problems with the environment and conflict with other persons Responsible behavior in handling the motorcycle can help to avoid such problems and con flicts To protect the future of motorcycle sport make sure that you use your motorcycle legally display environmental consciousness and respect the rights ...

Page 13: ...IMPORTANT INFORMATION 11 ...

Page 14: ...IMPORTANT INFORMATION 12 2 1 Overview of labels Supermoto T 601100 10 ...

Page 15: ...Information on operating substances and tires 4 Information on noise emission 5 Information on the fuel evaporation system 6 Information on chain tension 6 Information on suspension setting 7 Type label USA 8 Information on preparing for use 601102 01 Information on emission control ...

Page 16: ...IMPORTANT INFORMATION 14 600962 01 Type label Canada 600969 01 Information on operating substances and tires ...

Page 17: ...IMPORTANT INFORMATION 15 601103 01 Information on noise emission 600968 01 Information on the fuel evaporation system ...

Page 18: ...IMPORTANT INFORMATION 16 600966 01 Information on chain tension 601104 01 Information on suspension setting ...

Page 19: ...IMPORTANT INFORMATION 17 600963 01 Type label USA 600961 01 Information on preparing for use ...

Page 20: ...IMPORTANT INFORMATION 18 2 2 Overview of labels Supermoto R 601101 10 ...

Page 21: ...Information on operating substances and tires 4 Information on noise emission 5 Information on preparing for use 6 Information on the fuel evaporation system 7 Information on chain tension 7 Information on suspension setting 8 Type label USA 600964 01 Information on emission control ...

Page 22: ...IMPORTANT INFORMATION 20 600962 01 Type label Canada 600969 01 Information on operating substances and tires ...

Page 23: ...IMPORTANT INFORMATION 21 600965 01 Information on noise emission 600961 01 Information on preparing for use ...

Page 24: ...IMPORTANT INFORMATION 22 600968 01 Information on the fuel evaporation system 600966 01 Information on chain tension 600967 01 Information on suspension setting ...

Page 25: ...rnings Pay close attention to the notes warnings Info Various information and warning labels are affixed to the vehicle Do not remove information warning labels If they are missing you or others may not recognize potential hazards and may therefore be injured ...

Page 26: ...ins useful information and tips to help you operate and handle your motorcycle Only then will you find out how to best customize the motorcycle for your own use and how you can protect yourself from injury The owner s manual also contains important information on servicing the motorcycle The owner s manual is an important component of the motorcycle and should be handed over to the new owner if th...

Page 27: ...runo QC J3V 6B7 Phone 450 441 4451 x 4250 www ktmcanada com Tampering warning It is not permitted to make changes to the components of the noise damping system Federal law prohibits the following acts or causing thereof 1 The removal or rendering inoperative other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur...

Page 28: ...to the applicable laws and regulations Consumer rights Warranty claims should be submitted to an authorized KTM workshop If you are not satisfied please contact KTM North 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 Your righ...

Page 29: ...27 ...

Page 30: ...VIEW OF VEHICLE 28 3 1 View of vehicle front left side vehicle differs slightly from photo B00143 10 ...

Page 31: ...ICLE 29 1 Combination instrument 2 Filler cap 3 Rear mirror 4 Clutch lever 5 Seat 6 Handrails 7 Shock absorber compression damping 8 Shock absorber spring preload 9 Engine number 10 Shift lever 11 Oil level viewer ...

Page 32: ...VIEW OF VEHICLE 30 3 2 View of vehicle rear right side vehicle differs slightly from photo B00142 10 ...

Page 33: ... indicator switch horn button 3 Emergency OFF switch electric starter button 4 Hand brake lever 5 Fork spring preload fork rebound damping 6 Chassis number 7 Fork compression damping 8 Type label 9 Foot brake lever 10 Passenger footrests 11 Shock absorber rebound damping ...

Page 34: ...ERIAL NUMBERS 32 4 1 Chassis number type label 601117 10 The chassis number is stamped on the frame behind the steering head on the right 601116 10 The type label for the USA is fitted on the frame tube on the right ...

Page 35: ...he Code number key number 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 36: ...UMBERS 34 4 3 Engine number B00120 10 The engine number is stamped on the left side of the engine under the engine sprocket 4 4 Fork part number 700546 01 The fork part number is stamped on the inner side of the fork stub ...

Page 37: ...LOCATION OF SERIAL NUMBERS 35 4 5 Shock absorber part number 700547 01 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side ...

Page 38: ...ver is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 5 2 Hand brake lever 700549 01 The hand brake lever is fitted on the right side of the handlebar The front brake is engaged using the hand brake lever ...

Page 39: ... 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 5 4 Headlight flasher switch 700551 01 The headlight flasher switch is fitted on the left side of the handlebar Possible states Headlight flasher switch in basic position Headlight flasher switch pressed The headlight flasher switch high beam is oper ated in this pos...

Page 40: ...s to the central position after use Right turn signal on The turn signal switch is pressed to the right The turn signal switch automatically returns to the central position after use To switch off the turn signal press the turn signal switch towards the switch case 5 6 Horn button 700550 12 The horn button is fitted on the left side of the handlebar Possible states Horn button in basic position Ho...

Page 41: ...on circuit is closed and the engine can be started Steering locked In this position the ignition circuit is interrupted and the steering locked The ignition key can be removed 5 8 Immobilizer 400887 01 The electronic immobilizer secures the vehicle against unauthorized use The immobilizer is activated automatically and the engine electronics are locked when the ignition key is withdrawn The red wa...

Page 42: ...0 The emergency OFF switch is fitted on the right side of the handlebar Possible states Emergency OFF switch on This position is necessary for operation as it closes the ignition circuit Emergency OFF switch off In this position the ignition circuit is inter rupted a running engine stops and the engine cannot be started 5 10 Electric starter button 700552 11 The electric starter button is fitted o...

Page 43: ...achometer Indicator lights Display 5 12 Combination instrument function buttons 400921 10 You can change the display mode with the MODE button Possible display modes are the distance traveled ODO trip master 1 TRIP 1 trip mas ter 2 TRIP 2 and the ambient temperature Press the SET button to reset the trip master 1 function TRIP 1 and trip master 2 func tion TRIP 2 to 0 0 Button has no function ...

Page 44: ...tate of the motorcy cle Possible states The turn signal indicator lamp flashes green simultaneously with the turn signal The turn signal is switched on The idle speed indicator lamp lights up green The transmission is shifted to idle The high beam indicator lamp lights up blue The high beam is switched on The temperature warning lamp lights up red The coolant has reached a critical value The fuel ...

Page 45: ...r safety critical fault The immobilizer indicator lamp lights up or flashes red Status or error message for immobilizer alarm system The battery warning lamp lights up red The voltage in the vehicle system is too low 5 15 Combination instrument display 400892 01 When you switch on the ignition all display segments light up for one second as a function test ...

Page 46: ...17 front wheel with a series pro duction tire The display then changes to the last selected mode 5 16 Combination instrument speedometer 400838 10 The speed is shown in kilometers per hour km h or in miles per hour mph 5 17 Setting kilometers or miles Info If you change the unit the value ODO is retained and converted accordingly Making the setting according to the country ...

Page 47: ...tion Press the MODE button repeatedly until the ODO mode is active Keep the MODE button pressed until the display mode changes from km h to mph or from mph to km h 5 18 Combination instrument time 400893 11 The time is shown in area of the display Info After reconnecting the battery or changing the fuse the time must be reset ...

Page 48: ...e SET button pressed simultaneously The time display begins to flash Press the MODE button to set the hour Press the SET button to set the minute Keep the MODE button and the SET button pressed simultaneously The time is set 5 20 Combination instrument 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 b...

Page 49: ...ain 400840 01 Switch on the ignition by turning the ignition key to the ON position Press the MODE button repeatedly until the TRIP 1 mode is active Keep the SET button pressed The TRIP 1 display is set to 0 0 5 22 Combination instrument setting resetting TRIP 2 Info The TRIP 2 trip counter is always running and counts up to 999 9 The trip counter can be used to measure the distance covered during...

Page 50: ...s active Keep the SET button pressed The TRIP 2 display is set to 0 0 5 23 Combination instrument TRIP F display 400842 01 If the fuel level drops to the reserve mark the display automatically changes to TRIP F and starts to count from 0 0 regardless of the previous display mode Info Parallel to the TRIP F display the fuel warning light switches on ...

Page 51: ...C or F 5 25 Setting the temperature units Condition The motorcycle is stationary 400893 14 Switch on the ignition by turning the ignition key to the ON position Press the MODE button repeatedly until the ambient temperature is active Keep the MODE button pressed until the display mode changes from C to F or from F to C ...

Page 52: ...display when the ambient temperature rises above the specified value again Temperature 4 C 39 F 5 27 Combination instrument coolant temperature indicator 700124 01 The temperature display consists of 12 bars The more bars that light up the hotter the coolant When the upper bar lights up all bars in the display begin to flash and the temper ature warning lamp lights up Possible states Engine cold U...

Page 53: ...ressure off of the ignition key push down on the filler cap Damaged igni tion keys must be replaced Turn the ignition key 90 counterclockwise and remove the filler cap Info The filler cap has a tank air vent system 5 29 Closing the filler cap 700554 01 Put the filler cap back on and turn the ignition key 90 clockwise Remove the ignition key and fold down the cover ...

Page 54: ...ails are used for moving the motorcycle around If you carry a passenger the passenger can hold onto the handrails during the trip 5 31 Seat lock 600922 10 Seat lock is located at the rear under the tail light It can be locked with the ignition key ...

Page 55: ...dents 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 other objects during the jour ney Always remove the helmet lock before starting out The steel cable in the tool set can be used to lock a helmet to the vehicle to prevent it from being stolen ...

Page 56: ...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 5 35 Shift lever B00120 11 Shift lever is mounted on the left side of the engine ...

Page 57: ... can be seen in the photograph The neutral or idle position is between the first and second gear 5 36 Foot brake lever B00122 10 Foot brake lever is located in front of the right footrest The rear brake is activated using the foot brake lever ...

Page 58: ... 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 ...

Page 59: ...different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Warning Da...

Page 60: ...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 58 6 2 Running in the engine Do not exceed the specified engine speed and load during the running in period Guideline Maximum engine speed During the first 1 000 km 621 4 mi 6 500 rpm After the first 1 000 km 621 4 mi 9 500 r...

Page 61: ...gage cases 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 less visible to traffic behind you especially in the dark Check that your baggage is fixed properly at regular intervals Warning Danger of accidents Changed handling characteristics and longer s...

Page 62: ... center 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 400 kg 882 lb Maximum permissible front axle load 160 kg 353 lb Maximum permissible rear axle load 250 kg 551 lb ...

Page 63: ... the chain p 88 Check the tire condition p 112 Check the tire air pressure p 114 Check the front brake fluid level p 98 Check the rear brake fluid level p 102 Check the front brake linings p 100 Check the rear brake linings p 104 Check that the brake system is functioning properly Check the coolant level in the compensating tank p 149 Check that all controls are correctly adjusted and free to move...

Page 64: ... 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 ...

Page 65: ...tarting 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 safety start system You can only start the engine if the transmission is in neutral or if the clutch is...

Page 66: ...gnition 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 The passenger must be able to sit securely on the passenger seat The passenger must hold on to the rider or supporting strap firmly and place his her ...

Page 67: ...res have been run in Warning Danger of accidents Unstable handling characteristics Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational and with a full tank driver and passenger with protective clothing and helmet baggage Warning Danger of accidents Unstable handling characteristics due to slipped baggage Check the way your baggage is fixe...

Page 68: ...ch 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 After reaching maximum speed by fully opening the throttle grip turn the throttle back so it is open This will barely reduce the speed but fuel consumption will be consid erably lo...

Page 69: ...Danger of accidents If you brake too hard the wheels can lock Adapt your braking to the traffic situation and the road conditions Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake Check the brake ...

Page 70: ...bend Shift down to a lower gear that is appropriate to your speed On long downhill stretches use the braking effect of the engine Do this by changing down two gears but do not race the engine You will require less braking force and the brakes will not overheat 7 6 Stopping parking Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Sec...

Page 71: ...e brakes Shift the transmission to neutral Switch off the ignition by turning the ignition key to the OFF position Info If you switch off the engine with the emergency OFF switch but the ignition remains switched on at the ignition lock power continues to flow to most power consumers and the battery is soon discharged Therefore always switch off the engine with the ignition key the emergency OFF s...

Page 72: ...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 clothing that has come into contact with fuel Warning Environmental hazard Improper handling of fuel is a danger to the ...

Page 73: ... filler cap p 51 Low octane fuel Note Engine damage Low quality fuel damages the engine Operate the vehicle with fuel 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 Adjust the ignition curve to the fuel quality p 171 400970 12 Press the SET button for two seconds The fuel level warning lamp switches off TRIP...

Page 74: ... disc p 96 Check that brake lines are undamaged and free of leaks Check the rear brake fluid level p 102 Check the free travel of the foot brake lever p 97 Check the shock absorber and fork for leaks Perform a fork and shock absorber service if needed and depending on vehicle use Check the swingarm bearings x Check the wheel bearing for play x Check the tire condition p 112 Check the tire air pres...

Page 75: ...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 rectify the fluid level of the hydraulic clutch p 160 Check the fasteners for tightness x Change the coolant x Change the front brake fluid x Change the rear brake fluid x Check the clutch x Check the headlight setting p 141...

Page 76: ...SERVICE SCHEDULE 74 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 77: ...dlebar to the straight ahead position Align the work stand at the front with the adapters to the fork legs Front work stand 61029055300 Info Always jack up the rear of the motorcycle first Jack up the motorcycle at the front 9 2 Taking the front from the work stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Secure the mot...

Page 78: ... work stand Work stand adapter 61029055120 Work stand rear 61029055100 Stand the motorcycle upright align the work stand to the link fork and the adapters and jack up the motorcycle 9 4 Taking the rear from the workstand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Secure the motorcycle against falling over Remove the work ...

Page 79: ...ce to 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 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 9 6 Adjusting the c...

Page 80: ...ork legs Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline Supermoto R Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Supermoto T 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 suspension ...

Page 81: ...e zero position B00124 10 Turn adjusting screws clockwise until they stop 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 type Guideline Supermoto R Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Supermoto T Rebou...

Page 82: ... set for the weight of the rider and that of any baggage and a passenger and thus ensures a compromise between maneuverability and stability B00124 11 Turn adjusting screws clockwise until they stop 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 turns corresponding to the fork type Guideli...

Page 83: ...e spring preload has no influence on the rebound damping although the adjusting screws turn during the adjustment work However you should also adjust the rebound damping when you alter the spring preload 9 9 Bleeding the fork legs Lean the motorcycle on the side stand B00125 10 Remove bleeder screws briefly Any excess pressure escapes from the interior of the fork Mount and tighten the bleeder scr...

Page 84: ...nd not the riding speed of the motorcycle Changes in the low speed range settings have an impact on the high speed range and vice versa 9 11 Adjusting the low speed compression damping of the shock absorber Danger 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 wor...

Page 85: ... number of clicks corresponding to the shock absorber type Guideline Supermoto R Compression damping low speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Supermoto T Compression damping low speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping ...

Page 86: ...scription provided Your authorized KTM workshop will be glad to help Info The high speed setting can be seen during the fast compression of the shock absorber 700567 10 Turn adjusting screw clockwise all the way using a socket wrench Info Do not loosen nut Turn back counterclockwise the number of turns corresponding to the shock absorber type Guideline Supermoto R Compression damping high speed Co...

Page 87: ... 9 13 Adjusting the rebound damping of the shock absorber Danger 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 will be glad to help B00126 10 Turn adjusting screw clockwise up to the last perceptible click Turn back counterclockwise by the number of clic...

Page 88: ...dard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase suspension damping turn counterclockwise to reduce damping 9 14 Adjusting the spring preload of the shock absorber x 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 ride beh...

Page 89: ...present setting e g by measuring the length of the spring Take the weight off the rear wheel and swingarm Info The spring preload can be adjusted correctly only if the rear wheel and the swingarm are fully relieved of weight 700651 01 Loosen locking ring Turn adjusting ring until the spring is no longer under tension Hook wrench T106S Measure the overall spring length without a load Tension the sp...

Page 90: ...ll payload 13 mm 0 51 in Tighten locking ring 9 15 Checking the chain for dirt 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 88 9 16 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material ...

Page 91: ...nmental 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 210 After dry...

Page 92: ...k 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 700570 01 Lean the motorcycle on the side stand Shift the transmission to neutral In the area after the chain sliding guard press the chain upward toward the link fork and measure chain tension Info The upp...

Page 93: ...gine 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...

Page 94: ...eference marks 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 Make sure that chain adjusters are resting against adjusting screws Tighten nut Guideline Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Thread greased Info The wide adjustment range of the chain ...

Page 95: ... sprocket and engine sprocket 100132 10 Check the rear sprocket and engine sprocket for wear If the rear sprocket or engine sprocket is worn Replace the rear sprocket or engine sprocket x Info The rear sprocket engine sprocket and chain should always be changed together ...

Page 96: ...ximum distance at the longest chain section 272 mm 10 71 in If distance is greater than the specified measurement Replace the chain x Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out faster on old worn sprockets For safety reasons the chain has no chain joint B00113 01 Check the chain sliding guard for wear If the chain sliding guard ...

Page 97: ...shop will be glad to help 100135 10 Check the thickness of the brake disc in several places to see if it conforms to measure ment Info Wear reduces the thickness of the brake discs in area of the brake discs Brake discs wear limit Front 4 5 mm 0 177 in If the brake disc thickness is less than the specified value Change the brake discs x Check the brake discs for damage cracking and deformation If ...

Page 98: ...00480 10 Check the thickness of the brake disc in several places to see if it conforms to measure ment Info Wear reduces the thickness of the brake disc in area of the brake 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 damage cracks or deformation are ...

Page 99: ...er 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 can fail due to over heating Adjust free travel on foot brake lever according to specifications 600921 10 Move the foot brake lever back and forth between the end stop and the contact to the piston rod and check free travel Guideline Fre...

Page 100: ...ke system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brakes according to the service schedule Your authorized KTM workshop will be glad to help 700577 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Check the...

Page 101: ...r eyes rinse thoroughly with water and contact a doctor immediately Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brakes 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 flu...

Page 102: ... entered in the homologation documents Info Brake linings available in accessories shops are often untested and unapproved for use on KTM vehicles The structure and friction coefficient of the brake linings and therefore the brake power can vary considerably from the original KTM brake linings If brake linings other than those supplied as originals are used there is no guarantee that they correspo...

Page 103: ...have minimum thick ness Minimum thickness 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 cracking If damage or wear is encountered Change the front brake linings x 700638 01 Supermoto R Check all brake linings on both brake calipers to ensure they have minimum thick ness Minimum thickness 1...

Page 104: ...old brake fluid Change the brake fluid of the front and rear brakes according to the service schedule Your authorized KTM workshop will be glad to help B00131 10 Stand the vehicle upright Check the brake fluid level of the brake fluid reservoir If the fluid level reaches the MIN mark Add rear brake fluid x p 102 9 29 Adding rear brake fluid x Warning Danger of accidents Failure of the brake system...

Page 105: ...e brake fluid of the front and rear brakes 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 color Oil seals a...

Page 106: ... 1 p 206 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid immediately with water 9 30 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 107: ...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 wear is encountered Change the rear brake linings x 9 31 Removing the front wheel x Jack up the motorcycle at the rear p 76 Jack up the motorcycle at the front p 75 700639 10 Remove the screws from both brake calipers Press back the brake linings with...

Page 108: ... efficiency caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not dam aged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork 9 32 Installing the front wheel x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean th...

Page 109: ...ork position it and insert the wheel spindle Mount and tighten screw Guideline Bolt front axle M25x1 5 45 Nm 33 2 lbf ft 700639 11 Position the brake calipers and check that the brake linings are seated correctly Mount screws 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 F...

Page 110: ...rom the work stand p 76 700640 11 Pull the front brake and compress the fork powerfully a few times The fork legs straighten Fully tighten screws Guideline Screw fork stub M8 15 Nm 11 1 lbf ft 9 33 Removing the rear wheel x Jack up the motorcycle at the rear p 76 B00134 10 Remove nut Remove chain adjuster Pull out wheel spindle to the point where the chain adjuster is no longer in contact with the...

Page 111: ...cs are not dam aged Take the rear wheel carefully out of the swingarm without damaging the rim and or brake disc Info Do not operate the foot brake when the rear wheel is removed 9 34 Installing the rear wheel x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when nec...

Page 112: ... or worn Replace the wheel bearing x Remove bushing and bushing Clean and grease the roll surfaces of the bushing and the shaft seal rings Long life grease p 211 Fit the bushings Clean and grease the thread of the wheel spindle and nut Long life grease p 211 Clean the fixing locations on the brake caliper support and swingarm ...

Page 113: ...gs on the left and right chain adjusters must be in the same position relative to the reference marks 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 Take the rear from the work stand p 76 Check the chain tension p 90 9 35 Checking rear hub shock absorbers x Info The ...

Page 114: ... Checking the tire condition Warning Danger of accidents Uncontrollable handling characteristic caused by a flat tire For your own safety have damaged tires changed immediately Warning Danger 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 ...

Page 115: ...nfo The type condition and air pressure of the tires all have a major impact on the handling of the motorcycle Worn tires have a negative effect on vehicle handling especially on wet surfaces 400602 10 Check the front and rear tires for cuts run in objects and other damage If the tires exhibit cuts run in objects or other damage Change the tires Check the depth of the tread Info Note local nationa...

Page 116: ...state of wear If a tire is more than five years old Change the tires 9 37 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life 400695 01 Remove the dust cap Check the tire air pressure when the tires are cold Tire air pressure solo Front 2 2 bar 32 psi Rear...

Page 117: ...e Raise the rear of the seat push it towards the rear and remove it upwards Remove the ignition key from the seat lock 9 39 Mounting the seat B00136 01 Position front recesses of the seat on the oval head screws of the fuel tank lower the rear and simultaneously push it forward Both lugs must hook into the frame and locking bolt must be inserted into the lock housing The seat engages with an audib...

Page 118: ... 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 the side of the vehicle Mount the seat p 115 9 41 Removing the battery x Warning Risk of injury Battery acid and battery gases cause serious cauterization Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact ...

Page 119: ...quipment may be damaged Never operate the vehicle with a discharged battery or without a battery Switch off all power consumers and the engine Remove the seat p 115 700582 01 Disconnect negative minus cable of the battery 700583 01 Remove positive terminal cover Disconnect the positive plus cable of the battery Detach rubber band Pull the battery up and out of the battery rack ...

Page 120: ...ttery in the battery rack Info The terminals of the battery must face in the direction of travel Attach rubber band Reconnect the positive plus cable of the battery Position positive terminal cover 700582 10 Reconnect the negative minus cable of the battery Mount the seat p 115 Set the clock p 46 ...

Page 121: ...inse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Warning Environmental hazard Battery parts and acid are harmful to the environment Do not discard batteries with the household trash Dispose of a defective battery in an environmentally compatible manner Give the battery to your KTM dealer or to a recycling center that ac...

Page 122: ...d electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and sulfate destroying the battery The battery is maintenance free i e the acid level does not have to be checked S...

Page 123: ... Never remove lid Charge the battery with a maximum of 10 of the capacity specified on the bat tery housing Switch off the charger after charging Disconnect the battery Guideline The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the motorcycle is not in use 3 months Mount the seat p 115 9 44 Changing the main fuse Warning Fire hazard The elect...

Page 124: ...ine Remove the seat p 115 700589 01 Remove protection covers Remove the faulty main fuse Info A defective fuse can be identified by the burned out fuse wire A reserve fuse is located in the starter relay Install a new main fuse Fuse 58011109130 p 196 Tip Place the spare fuse in the starter relay so that it is available if needed Attach the protection covers Mount the seat p 115 ...

Page 125: ...the prescribed amperage Never by pass or repair fuses Info The fuse box containing the fuses of individual power consumers is located under the seat Switch off all power consumers and the engine Remove the seat p 115 700584 01 Open fuse box cover Check the fuses Info A defective fuse can be identified by the burned out fuse wire Spare fuses are also found in the storage compartment Remove the faul...

Page 126: ...N 10A radiator fan Fuse POWER RELAY 10A ignition EFI control unit Fuse ACC1 CLOCK 10A combination instrument socket supplementary devices permanent positive alarm system optional Fuse ACC2 10A supplementary equipment accessories connected to the ignition switch Fuse ABS OPTIONAL not used Use spare fuses with the correct rating only Fuse 58011109110 p 196 Fuse 58011109115 p 196 Tip Insert the spare...

Page 127: ...n 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 Switch off all power consumers and the engine B00137 10 Supermoto R Remove screws 700591 10 Cover the fender with a cloth Swing the headlight mask forward and pull it upward out of holding lugs ...

Page 128: ...k removed for this model Removal is not necessary 700592 10 Disconnect plug in connector Remove rubber cap 700593 01 Push off retaining clamp on both sides squeeze and fold down Remove headlight bulb Position the new headlight bulb in the headlight housing Low beam high beam H4 socket P43t p 196 Info Insert the headlight bulb so that the bayonet lugs latch into the slots ...

Page 129: ...MAINTENANCE WORK ON FRAME AND ENGINE 127 Position the retaining clamp 700592 11 Mount rubber cap Position plug in connection 700591 11 Supermoto R Position holes onto holding lugs ...

Page 130: ... ft 700604 01 Supermoto T Mount the cover Check that the lighting is functioning properly 9 47 Changing the parking light bulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Switch off all power consumers and the engine ...

Page 131: ... 10 Cover the fender with a cloth Swing the headlight mask forward and pull it upward out of holding lugs 700604 01 Supermoto T Remove the cover Info For purposes of illustration only the following steps are shown with the headlight mask removed for this model Removal is not necessary ...

Page 132: ...ing light carefully out of the holder Remove the bulb Position a new light bulb in the holder Parking light W5W socket W2 1x9 5d p 196 Carefully position the holder with the bulb into the holder in the headlight 700591 12 Supermoto R Position holes onto holding lugs ...

Page 133: ... screws M6 10 Nm 7 4 lbf ft 700604 01 Supermoto T Mount the cover Check that the lighting is functioning properly 9 48 Changing the turn signal bulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting ...

Page 134: ...l it stops Turn signal RY10W socket BAU15s p 197 Check the turn signal to make sure it is functioning properly Position the diffuser Insert the screw and first turn it counterclockwise until it engages in the thread Tighten the screw slightly 9 49 Changing the brake light bulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the refle...

Page 135: ...MAINTENANCE WORK ON FRAME AND ENGINE 133 B00138 10 Remove screws Remove screws on the left and right rear side part Remove the rear side part 700599 10 Remove screws Remove the top part ...

Page 136: ...t turn it counterclockwise and pull it out of the socket Press the new bulb carefully into the socket and turn it clockwise until it stops Brake light PR21W socket BAW15s p 197 Insert the bulb socket into the tail light and turn clockwise until it stops 700599 11 Position the rear top part Mount and tighten screws Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft ...

Page 137: ...ighten screws on the left and right rear side part Guideline Screw rear side part EJOT Initial screw con nection 3 3 Nm 2 43 lbf ft Subsequent screw connection 2 Nm 1 5 lbf ft 700597 11 Position the grab handles Mount and tighten screws Guideline Remaining chassis screws M8 25 Nm 18 4 lbf ft Mount the seat p 115 Check that the brake light system is functioning properly ...

Page 138: ...g the tail light bulbs Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting 700597 10 Remove screws Remove the grab handles ...

Page 139: ...MAINTENANCE WORK ON FRAME AND ENGINE 137 B00138 10 Remove screws Remove screws on the left and right rear side part Remove the rear side part 700599 10 Remove screws Remove the top part ...

Page 140: ...ket Remove the bulb Position a new light bulb in the holder Tail light WR5W socket W2 1x9 5d p 197 Carefully position the holders with the bulbs into the holder in the tail light 700599 11 Position the rear top part Mount and tighten screws Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft ...

Page 141: ...tighten screws on the left and right rear side part Guideline Screw rear side part EJOT Initial screw con nection 3 3 Nm 2 43 lbf ft Subsequent screw connection 2 Nm 1 5 lbf ft 700597 11 Position the grab handles Mount and tighten screws Guideline Remaining chassis screws M8 25 Nm 18 4 lbf ft Mount the seat p 115 Check that the tail light bulbs are functioning properly ...

Page 142: ...mp 700602 01 Remove screws Remove the license plate lamp cover 700603 01 Pull holder carefully out of the bracket Remove the bulb Position a new light bulb in the holder License plate lamp W5W socket W2 1x9 5d p 197 Carefully position the holder with the bulb into the bracket ...

Page 143: ...he center of the headlight Make another mark at a distance of under the first mark Guideline Distance 5 cm 2 in Park the vehicle at a distance of vertically in front of the wall and switch on the low beam headlight Guideline Distance 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 low...

Page 144: ...ight dark boundary must be exactly on the lower mark applied in Checking headlight adjustment Info Turn clockwise to increase the light range turn counterclockwise to reduce the light range B00139 10 Supermoto T Turn adjusting wheel to adjust the headlight range Guideline For a motorcycle with rider and with luggage and a passenger if applicable the light dark boundary must be exactly on the lower...

Page 145: ... key second black ignition key available The following procedure deactivates all activated black ignition keys that are not included in the procedure Press the emergency OFF switch into the position 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 flas...

Page 146: ...portant to prevent misuse of the lost black ignition key Press the emergency OFF switch into the position 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 programm...

Page 147: ...ition key in the ignition lock Switch on the ignition by turning the ignition key to the ON position FI Warning lamp MIL lights up switches off and then starts to flash Immobilizer indicator lamp lights up switches off briefly and lights up again Switch off the ignition by turning the ignition key to the OFF position Remove the black ignition key To activate further ignition keys repeat the last 4...

Page 148: ...ng system resulting from heat is regulated by a valve in the radia tor cap This permits the specified coolant temperature without causing any malfunctions 125 C 257 F 700621 10 Cooling takes place by means of the air stream and a radiator fan 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 ca...

Page 149: ...diately 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 reach of children Condition The engine is cold Stand the motorcycle upright on a horizontal surface Reset the fuel tank p 154 700626 10 Remove radiator cap and plug from...

Page 150: ...d the cooling system x p 151 Mount cap of the compensating tank 700625 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 determine the reason for the coolant loss Alternative 1 Coolant p 206 Alternative 2 Coolant mixed ready to use p 206 If more coolant needed to be added than the specif...

Page 151: ...ets 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 reach of children Condition The engine is cold The radiator is completely full Stand the motorcycle on a horizontal surface 700622 10 Check ...

Page 152: ...r hoses or other cooling 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 ...

Page 153: ...nt Mount screw with a new seal ring and tighten it Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft 9 59 Filling bleeding the cooling system x Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and ...

Page 154: ...move bleeder screw 0 0 A A 400677 10 Position the vehicle as shown and secure it against rolling Height difference must be reached Guideline Height difference 50 cm 19 7 in Info 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 ...

Page 155: ... 149 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and run it until it reaches operating temperature Six bars of the temperature display ...

Page 156: ...54 9 60 Reinstalling the fuel tank Remove the seat p 115 Supermoto T Remove the mask spoiler p 157 B00141 10 Remove screws and the spoiler on both sides B00147 10 Remove screw on both sides Info The fuel hoses do not need to be disconnected ...

Page 157: ...lly push the fuel tank back 9 61 Positioning the fuel tank Carefully push the fuel tank forward Supermoto T The fuel tank fixations must engage in the recesses 700652 10 Supermoto R Mount and tighten screw with the collar bushing Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft ...

Page 158: ...e on both sides Check the fuel tank for tightness Guideline Remaining chassis screws M8 25 Nm 18 4 lbf ft Check the routing of the fuel lines B00141 11 Position the spoilers on both sides Mount and tighten screws Guideline Screw spoiler M6 8 Nm 5 9 lbf ft Supermoto T Install the mask spoiler p 158 Mount the seat p 115 ...

Page 159: ...MAINTENANCE WORK ON FRAME AND ENGINE 157 9 62 Removing the mask spoiler Supermoto T 700632 01 Remove screws 700634 01 Remove screws Remove the mask spoiler ...

Page 160: ... 158 700633 01 Remove screws Remove the inside trim of the mask spoiler Repeat the operation on the opposite side 9 63 Installing the mask spoiler Supermoto T 700633 10 Position the inside trim of the mask spoiler Mount and tighten screws ...

Page 161: ...he basic position of the clutch lever Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding ...

Page 162: ...r hand size by turning adjusting screw When adjusting the clutch lever make sure that there is a minimum clearance to other parts of the vehicle Guideline Minimum clearance 5 mm 0 2 in 9 65 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 Move the clutch fluid reservoir mounted on the handle...

Page 163: ...ion Move the throttle grip backwards and forwards to ascertain the play in the throttle cable Play in throttle cable 3 5 mm 0 12 0 2 in If the throttle cable play does not meet specifications Adjust the play in the throttle cable x p 162 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there...

Page 164: ...ottle cable by turning adjusting screw Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Tighten counter nut 9 68 Checking the engine oil level Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without a...

Page 165: ...wait one minute before checking the level Check the engine oil level at oil level viewer The engine oil level must be between the upper and lower marking If the engine oil level is not at the specified level Add engine oil p 170 9 69 Changing the engine oil and filter cleaning the oil screens x B00119 01 Drain the engine oil and filter clean the oil screens x p 164 Fill up with engine oil x p 168 ...

Page 166: ...es 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 regulations Info Drain the engine oil only when the engine is warm 700611 10 Place a suitable container under the engine Remove the oil drain plug with the magnet and...

Page 167: ... Remove screws and cover 700612 10 Pull oil screen out of the engine case with pliers 700613 10 Place a suitable container under the engine Remove oil drain plug Fully drain the engine oil out of the oil tank Remove screws and move oil line to one side ...

Page 168: ...il filter out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Clean all oil screens and oil drain plugs with a magnet Clean all sealing surfaces 700618 10 Insert oil filter Lubricate the O ring of the oil filter cover Install oil filter cover Mount and tighten the screws Guideline Remaining engine screws M5 6 Nm 4 4 lbf ft Position the oil line Mount an...

Page 169: ...Check seal ring of the oil sieve for damage and correct seating Insert oil sieve into the oil tank 700613 10 Position oil line Mount and tighten screws Guideline Remaining engine screws M6 10 Nm 7 4 lbf ft Mount oil drain plug with the magnet and new seal and tighten Guideline Oil drain plug with magnet M12x1 5 25 Nm 18 4 lbf ft ...

Page 170: ... 8 lbf ft 700616 10 Slide oil sieve into the engine case with the TOP marking facing up Check the form ring in cover for damage and correct seating Position the cover Mount and tighten the screws Guideline Screw clutch cover M6 10 Nm 7 4 lbf ft 9 71 Filling up with engine oil x Info Too little engine oil or poor quality engine oil results in premature wear to the engine ...

Page 171: ...nhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and run it until it reaches operating temperature Six bars of the temperature display light up Check the lubrication system for leaks Switch off the en...

Page 172: ... be corrected when the engine is warm 700619 10 Remove plug and add engine oil to the top marking Condition External temperature 0 C 32 F Engine oil SAE 10W 50 p 207 Condition External temperature 0 C 32 F Engine oil SAE 5W 40 p 207 Info For optimal performance of the engine oil do not mix different types of engine oil We recommend changing the engine oil if necessary Mount the plug ...

Page 173: ...e rating of 95 or higher can be used 9 74 Adjusting the ignition curve to the fuel quality Switch off the ignition by turning the ignition key to the OFF position Remove the seat p 115 To activate the ignition curve for low octane fuel Note Engine damage Low quality fuel damages the engine Operate the vehicle with fuel with an octane rating below 95 ROZ 95 RON 95 PON 91 for no more than one tank f...

Page 174: ...MAINTENANCE WORK ON FRAME AND ENGINE 172 Mount the seat p 115 ...

Page 175: ...ntrol unit 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 176: ... indicator 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 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 lam...

Page 177: ...p FI 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 FI of warning lamp MIL 09 Warning lamp FI 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...

Page 178: ...ir temperature sensor input signal too high Blink code FI of warning lamp MIL 14 Warning lamp FI 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 FI of warning lamp MIL 15 Warning lamp FI MIL flashes 1x long 5x short Error level condition Rollover sensor A D type input signal too low Rol...

Page 179: ...or level condition Power supply circuit fault Blink code FI of warning lamp MIL 25 Warning lamp FI MIL flashes 2x long 5x short Error level condition Side stand A D type malfunction in circuit Blink code FI of warning lamp MIL 33 Warning lamp FI MIL flashes 3x long 3x short Error level condition Injector cylinder 1 circuit fault Blink code FI of warning lamp MIL 34 Warning lamp FI MIL flashes 3x l...

Page 180: ... level condition Fuel pump control interruption short circuit to ground Fuel pump control input signal too high Blink code FI of 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 FI of warning lamp MIL 46 Warn...

Page 181: ...ning lamp FI MIL flashes 5x long 3x short Error level condition Fuel evaporation system short circuit to ground or open circuit Fuel evaporation system input signal too high Blink code FI of warning lamp MIL 54 Warning lamp FI 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 FI of warnin...

Page 182: ...old absolute pressure sensor cylinder 2 connection leaks Blink code FI of warning lamp MIL 81 Warning lamp FI MIL flashes 8x long 1x short Error level condition Immobilizer control unit circuit fault Blink code FI of warning lamp MIL 91 Warning lamp FI MIL flashes 9x long 1x short Error level condition Malfunction in CAN bus communication ...

Page 183: ...trol unit 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 safet...

Page 184: ...on in cooling system Drain the coolant x p 150 Fill bleed the cooling system x p 151 Buckled or damaged radiator hose Change the radiator hose x Fuse FAN blown Change the fuses of individual power consumers p 123 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 151 Warning lamp FI MIL l...

Page 185: ... functional Fuse HORN BRAKE LIGHT SPEEDO blown Change the fuses of individual power consumers p 123 Battery discharged Ignition not switched off when vehicle was parked Recharge the battery x p 119 Battery is not charged by the alternator Check the charging voltage x Combination instrument shows nothing in the display Fuse ACC1 CLOCK blown Change the fuses of individual power consumers p 123 Speed...

Page 186: ...ulations 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 Close off the exhaust system to keep water from entering Remove coarse dirt particles with a gentle spray of water Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush Motorcycle cleaner p 211 ...

Page 187: ...er at inaccessible positions in the engine and on the brakes to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 88 Treat bare metal parts except for brake discs and exhaust system with anti corrosion materials Cleaning and preserving materials for metal rubber and plastic p 210 Treat all painted parts with a mild paint polish High luster poli...

Page 188: ...n it with cold water Warm water would enhance the corrosive effects of salt Clean the motorcycle p 184 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with a wax based anti corrosion substance Info To prevent serious reduction of the braking efficiency make sure no anti corrosion substance gets on to the brake discs After use on salted roads clean the motorc...

Page 189: ...fill up with fresh fuel when you put the motorcycle back into opera tion Clean the motorcycle p 184 Change the engine oil and filter clean the oil screens x p 163 Check the antifreeze and coolant level p 147 Check the tire air pressure p 114 Remove the battery x p 116 Recharge the battery x p 119 Guideline Storage temperature of battery without direct sunshine 0 35 C 32 95 F The storage place shou...

Page 190: ...m up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 15 2 Putting into operation after storage Take the front from the work stand p 75 Take the rear from the work stand p 76 Recharge the battery x p 119 Install the battery x p 118 Set the clock p 46 Refuel p 70 Carry out checks before putting into operation p 61 Take a test ride ...

Page 191: ...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 Multidisc clutch in oil bath hydraulicall...

Page 192: ...R8DI Spark plug electrode gap 0 8 mm 0 031 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 400 1 500 rpm Cold start device Electric starter 16 1 Capacity engine oil Engine oil 3 80 l 1 004 US gal External temperature 0 C 32 F Engine oil SAE 10W 50 p 207 External temperature 0 C 32 F Engine oil SAE 5W 40 p 207 16 2 Capacity coolant Coolant 2 30 l 2 43 qt Coolant...

Page 193: ...6 10 Nm 7 4 lbf ft Screw in alternator cover M6 10 Nm 7 4 lbf ft Screw bearing bolt in alternator cover M6 10 Nm 7 4 lbf ft Loctite 243 Screw camshaft bearing support M6 10 Nm 7 4 lbf ft Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch spring M6 10 Nm 7 4 lbf ft Screw engine case M6 10 Nm 7 4 lbf ft Screw freewheel holder M6 10 Nm 7 4 lbf ft Loctite 243 Screw freewheel ring M6 13 Nm 9 6 lbf ft ...

Page 194: ...ng chain guide rail M8 15 Nm 11 1 lbf ft Loctite 243 Bearing bolt timing chain tensioning rail M8 20 Nm 14 8 lbf ft Loctite 243 Screw camshaft bearing support M8 Step 1 10 Nm 7 4 lbf ft Step 2 18 Nm 13 3 lbf ft Screw clutch cover M8 15 Nm 11 1 lbf ft Screw cylinder head M8 Step 1 18 Nm 13 3 lbf ft Step 2 23 Nm 17 lbf ft Loctite 243 Stud exhaust flange M8 15 Nm 11 1 lbf ft Bearing bolt timing gears...

Page 195: ... 2nd cylinder M12x1 5 25 Nm 18 4 lbf ft Spark plug M12x1 5 12 Nm 8 9 lbf ft Plug oil filter housing M14x1 5 15 Nm 11 1 lbf ft Loctite 243 Bleeder flange alternator cover M16x1 5 10 Nm 7 4 lbf ft Loctite 243 Plug timing chain tensioner M16x1 5 20 Nm 14 8 lbf ft Rotor screw M16x1 5 150 Nm 110 6 lbf ft Loctite 243 Nut balancer shaft M20x1 5 120 Nm 88 5 lbf ft Loctite 243 Nut engine sprocket M20x1 5 1...

Page 196: ...TECHNICAL DATA ENGINE TIGHTENING TORQUES 194 Nut primary gear M33LHx1 5 130 Nm 95 9 lbf ft Loctite 243 ...

Page 197: ...ble disc brake with radially screwed four piston brake calipers float mounted brake discs Rear Single disc brake with dual piston brake caliper rigid mounted brake disc Brake discs diameter Front 305 mm 12 01 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 2 bar 32 psi Rear 2 2 bar 32 psi Tire air pressur...

Page 198: ... R 189 kg 417 lb Weight without fuel approx Supermoto T 196 kg 432 lb Maximum permissible front axle load 160 kg 353 lb Maximum permissible rear axle load 250 kg 551 lb Maximum permissible total weight 400 kg 882 lb Battery YTZ14S Battery voltage 12 V Nominal capacity 11 2 Ah maintenance free Fuse 58011109110 10 A Fuse 58011109115 15 A Fuse 58011109130 30 A 18 1 Lighting equipment Low beam high be...

Page 199: ...relli DRAGON SUPERCORSA PRO Supermoto T 120 70 ZR 17 M C 58W TL Continental ContiSportAttack 180 55 ZR 17 M C 73W TL Continental ContiSportAttack Additional information is available in the Service section under http www ktm com 18 3 Capacity fuel Total fuel tank capacity approx Supermoto T 19 l 5 US gal Super unleaded ROZ 95 RON 95 PON 91 p 209 Total fuel tank capacity approx Supermoto R 15 l 4 US...

Page 200: ...nd damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload Preload Adjuster Comfort 5 turns Standard 5 turns Sport 3 turns Full payload 3 turns Spring length with preload spacer s 386 mm 15 2 in Spring rate Medium standard 7 5 N mm 42 8 lb in Fork length 877 mm 34 53 in Air chamber length 100 20 mm 3 94 0 79 in Fork oil per fork leg 750 ml 25 36 fl oz For...

Page 201: ...damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Spring preload Preload Adjuster Comfort 5 turns Standard 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 110 10 30 mm 4 33 0 39 1 18 in Fork oil per fork leg 742 ml 25 09 fl oz...

Page 202: ... clicks Standard 20 clicks Sport 15 clicks 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 Comfort 11 mm 0 43 in Standard 11 mm 0 43 in Sport 11 mm 0 43 in Full payload 13 mm 0 51 in Spring rate ...

Page 203: ...absorber oil SAE 2 5 50180342S1 p 208 20 2 Supermoto T Shock absorber part number 15 18 7E 43 Shock absorber WP Suspension 4618 BAVP DCC Compression damping low speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks 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...

Page 204: ... Standard 11 mm 0 43 in Sport 11 mm 0 43 in Full payload 13 mm 0 51 in Spring rate Medium standard 140 N mm 799 lb in Spring length 200 mm 7 87 in Gas pressure 10 bar 145 psi Static sag 20 mm 0 79 in Fitted length 372 mm 14 65 in Shock absorber fluid Shock absorber oil SAE 2 5 50180342S1 p 208 ...

Page 205: ... ft Screw windshield Supermoto T M5 3 3 Nm 2 43 lbf ft Nut tail light M6 8 Nm 5 9 lbf ft Remaining chassis nuts M6 15 Nm 11 1 lbf ft Remaining chassis screws M6 10 Nm 7 4 lbf ft Remaining screws on fuel tank M6 3 3 Nm 2 43 lbf ft Screw cable guide Supermoto T M6 2 Nm 1 5 lbf ft Screw chain sliding guard M6 6 Nm 4 4 lbf ft Loctite 243 Screw foot brake cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw ...

Page 206: ...w ignition lock ratchet screw M8 Loctite 243 Screw mask holder Supermoto T M8 15 Nm 11 1 lbf ft Loctite 243 Screw rear brake disc M8 30 Nm 22 1 lbf ft Loctite 243 Screw rear footrest bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw side stand holder 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 Engine carrying screw M10 45 Nm 33...

Page 207: ...line M14x1 5 45 Nm 33 2 lbf ft Loctite 577 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 swingarm pivot M19x1 5 130 Nm 95 9 lbf ft Thread greased Screw steering head M20x1 5 12 Nm 8 9 lbf ft Bolt front axle M25x1 5 45 Nm 33 2 lbf ft Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Thread greased ...

Page 208: ...x products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant also in countries with high temperatures Use of low quality antifreeze can lead to corrosion and foaming KTM recommends Motorex products Mixture ratio Antifreeze protection 25 45 C 13 49 F 50 corrosion inhibitor antifreeze 50 distilled water Coolant mixed ready to us...

Page 209: ...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 212 SAE p 212 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 Supplie...

Page 210: ...lic 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 212 SAE 2 5 Guideline Use only oils that comply with the specified standards se...

Page 211: ...SUBSTANCES 209 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91 ...

Page 212: ... road use Guideline KTM recommends Motorex products Supplier Motorex Chain Lube 622 Strong Cleaning and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Supplier Motorex Protect Shine 645 High luster polish for paint Guideline KTM recommends Motorex products Supplier Motorex Moto Polish ...

Page 213: ...e KTM recommends Motorex products Supplier Motorex Fett 2000 Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Universal ...

Page 214: ...ce intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Stan dard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils ...

Page 215: ... brake checking 102 Brake light bulb changing 132 Brake linings 100 front brake checking 100 rear brake checking 104 Brakes 67 Braking 67 C Chain checking 93 cleaning 88 dirt checking 88 Chain tension adjusting 91 checking 90 Chassis number 32 Cleaning 184 185 Clutch checking correcting fluid level 160 Clutch lever 36 basic position adjusting 159 Combination instrument 41 clock setting 46 coolant ...

Page 216: ...Cooling system 146 filling bleeding 151 D Display 43 E Electric starter button 40 Emergency OFF switch 40 Engine running in 58 Engine number 34 Engine oil adding 170 changing 163 draining 164 refilling 168 Engine oil level checking 162 Engine sprocket checking 93 Environment 10 F Filler cap closing 51 opening 51 Foot brake lever 55 free travel checking 97 Fork 77 compression damping adjusting 77 f...

Page 217: ...3 mounting on vehicle 116 Horn button 38 I Ignition curve adjusting to fuel quality 171 plug in connector 171 Ignition key activating deactivating 143 Ignition lock 39 Immobilizer 39 Indicator lamps 42 K Key number 33 L License plate lamp changing 140 Light switch 37 Loading the vehicle 58 M Main fuse changing 121 Maintenance 8 Mask spoiler installing 158 removing 157 Motorcycle cleaning 184 jacki...

Page 218: ...ks before putting into operation 61 R Rear hub shock absorber checking 111 Rear sprocket checking 93 Rear wheel installing 109 removing 108 Refueling fuel 70 Riding 64 starting up 63 S Seat mounting 115 removing 115 Seat lock 52 Service schedule 72 74 Shift lever 54 Shifting 64 Shock absorber 77 compression damping general 82 compression damping high speed adjusting 84 compression damping low spee...

Page 219: ...90 engine tightening torques 191 194 fork 198 199 shock absorber 200 202 Tire air pressure checking 114 Tire condition checking 112 Tool set 53 Transport 9 Troubleshooting 181 183 Turn signal bulb changing 131 Turn signal switch 38 Type label 32 U Use definition 8 V View of vehicle front left side 28 rear right side 30 W Warning of slippery roads 50 Warranty 8 Work rules 9 ...

Page 220: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 01 2010 Photo Mitterbauer 3211562en 3211562en ...

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KTM 990 Supermoto R, Owner'S Manual

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