KTM F4303U1 Owner'S Manual Download

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BRAKE SYSTEM 13

F00847-11

–

Detach spring

–

Release nut

and use screw

to adjust the specified free

travel

Guideline

Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in)

Info

The range of adjustment is limited.

–

Hold screw

and tighten nut

–

Attach spring

13.9

Checking the rear brake fluid level

Warning

Danger of accidents

An insufficient brake fluid level will cause the brake system to fail.

If the brake fluid level drops below the

MIN

marking, the brake system is leaking or the brake linings are

worn down.

–

Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)

Warning

Danger of accidents

Old brake fluid reduces the braking effect.

–

Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)

S04752-10

–

Stand the vehicle upright.

–

Check the brake fluid level in the brake fluid reservoir.
» If the fluid level reaches the

MIN

marking

–

Add rear brake fluid.

(

p. 72)

Summary of Contents for F4303U1

Page 1: ...OWNER S MANUAL 2021 390 DUKE Art no 3214321en ...

Page 2: ......

Page 3: ...articular model without prior notice KTM accepts no liability for delivery options deviations from fig ures and descriptions misprints and other errors The models portrayed partly contain special equipment that does not belong to the regular scope of supply 2021 KTM Sportmotorcycle GmbH Mattighofen Austria All rights reserved Reproduction even in part as well as copying of all kinds is permitted o...

Page 4: ...ing lock 17 6 7 Locking the steering 17 6 8 Unlocking the steering 18 6 9 Opening fuel tank filler cap 18 6 10 Closing the fuel tank filler cap 19 6 11 Seat lock 19 6 12 Tool set 20 6 13 Grab handles 20 6 14 Passenger foot pegs 20 6 15 Shift lever 20 6 16 Foot brake lever 21 6 17 Side stand 21 7 COMBINATION INSTRUMENT 22 7 1 Combination instrument 22 7 2 Activation and test 22 7 3 Day Night mode 2...

Page 5: ...2 17 Fitting front spoiler 65 13 BRAKE SYSTEM 66 13 1 Anti lock braking system ABS 66 13 2 Adjusting the basic position of the hand brake lever 67 13 3 Checking the brake discs 67 13 4 Checking the front brake fluid level 67 13 5 Adding the front brake fluid 68 13 6 Checking the front brake linings 69 13 7 Checking the free travel of foot brake lever 70 13 8 Adjusting the free travel of the foot b...

Page 6: ...06 22 TECHNICAL DATA 108 22 1 Engine 108 22 2 Engine tightening torques 109 22 3 Capacities 111 22 3 1 Engine oil 111 22 3 2 Coolant 111 22 3 3 Fuel 111 22 4 Chassis 111 22 5 Electrical system 112 22 6 Tires 112 22 7 Fork 113 22 8 Shock absorber 113 22 9 Chassis tightening torques 113 23 DECLARATIONS OF CONFORMITY 117 23 1 Declarations of conformity 117 24 SUBSTANCES 118 25 AUXILIARY SUBSTANCES 12...

Page 7: ...ned experts using the special tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a testing step Indicates a voltage measurement Indicates a current measurement Indicates the end of an activity including potential rework 1 2 Formats used The typographical formats used in this document a...

Page 8: ...s included carefully The safety instructions are highlighted in the text and are referred to at the relevant passages Info Various information and warning labels are attached in prominent locations on the product described Do not remove any information or warning labels If they are missing you or others may not recognize dangers and may therefore be injured 2 4 Degrees of risk and symbols Danger I...

Page 9: ...anger Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others Do not operate the vehicle if you are not fit to ride due to alcohol drugs or medication Do not operate the vehicle if you are physically or mentally impaired Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is suffi...

Page 10: ...e g Precote has already been applied to a new part do not apply any additional thread locker After disassembly clean the parts that are to be reused and check them for damage and wear Change damaged or worn parts After completing a repair or service work check the operating safety of the vehicle 2 9 Environment If you use your motorcycle responsibly you can ensure that problems and conflicts do no...

Page 11: ...d again by the new owner The Owner s Manual can be downloaded several times using the QR code or the link on the delivery certificate The Owner s Manual is also available for download from your authorized KTM dealer and on the KTM website A printed copy can also be ordered from your authorized KTM dealer International KTM Website KTM COM ...

Page 12: ...ice A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly carried out as described in the Owner s Manual An incorrect suspension setting can lead to damage and breakage of chassis components Use of the vehicle under difficult conditions such as dusty environments heavy rain high heat or with a heavy load...

Page 13: ...CLE 4 11 4 1 View of vehicle front left example S04740 10 1 Combination instrument 2 Clutch lever p 15 3 Front rider s seat 4 Passenger seat 5 Grab handles p 20 6 Seat lock p 19 7 Side stand p 21 8 Shift lever p 20 ...

Page 14: ...p 16 2 Menu buttons p 16 2 Turn signal switch p 16 2 Horn button p 16 3 Ignition and steering lock p 17 4 Emergency OFF switch p 17 4 Start button p 17 5 Throttle grip p 15 6 Hand brake lever p 15 7 Vehicle identification number p 13 7 Type label p 13 8 Foot brake lever p 21 9 Passenger foot pegs p 20 ...

Page 15: ... 5 2 Type label 402174 10 EU JP AR BR CN CO MY PH TH 390 DUKE B D 3 EU The type label 1 is on the right of the frame behind the steering head 402772 10 390 DUKE AU The type label 1 is on the left of the frame behind the steer ing head 5 3 Engine number 402486 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket ...

Page 16: ...und on the KEYCODECARD Info The key number is needed to order a replacement key Keep the KEYCODECARD in a safe place If at least one ignition key is still available a spare key can be produced If an ignition key is no longer present the entire lock system must be replaced ...

Page 17: ...nt brake is engaged using the hand brake lever 6 3 Throttle grip F00784 11 The throttle grip 1 is fitted on the right side of the handlebar 6 4 Switches on the left side of the handlebar 6 4 1 Combination switch The combination switch is fitted on the left side of the handlebar F00785 10 Overview of the left combination switch 1 Light switch p 16 2 Menu buttons p 16 3 Turn signal switch p 16 4 Hor...

Page 18: ...Button 1 is the UP button Button 2 is the DOWN button Button 3 is the SET button Button 4 is the BACK button 6 4 4 Turn signal switch F00787 11 Turn signal switch 1 is fitted on the left side of the handlebar Possible states Turn signal off Turn signal switch pushed toward the switch housing Left turn signal on Turn signal switch pressed to the left The turn signal switch returns automatically to ...

Page 19: ...n the basic position The start button is pressed In this position the starter motor is actuated 6 6 Ignition and steering lock F00788 01 The ignition and steering lock is located in front of the upper triple clamp Possible states Ignition off OFF In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start The ignition key can be removed Ignit...

Page 20: ...s Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case ...

Page 21: ...l is highly flammable toxic and a health hazard Check that the fuel tank filler cap is locked cor rectly after closing Change your clothing if fuel spills on them Rinse the affected area immediately with plenty of water in the event of contact with the skin Fold down the fuel tank filler cap Turn the ignition key 90 clockwise Push down the fuel tank filler cap and turn the ignition key countercloc...

Page 22: ...rry a passenger the passenger can hold onto the grab handles during the trip 6 14 Passenger foot pegs F00866 10 The passenger foot pegs can be folded up and down Possible states Passenger foot pegs folded up For operation without a pas senger Passenger foot pegs folded down For operation with a pas senger 6 15 Shift lever 401950 10 Shift lever 1 is mounted on the left side of the engine ...

Page 23: ...and 402029 10 The side stand 1 is located on the left of the vehicle The side stand is used for parking the motorcycle Info The side stand must be folded up during motorcycle use The side stand is coupled with the safety starting system follow the riding instructions Possible states Side stand folded out The vehicle can be supported on the side stand The safety starting system is active Side stand...

Page 24: ...nation instrument Test The welcome text appears on the display and the indicator lamps are briefly activated for a function check 7 3 Day Night mode M01578 01 Day mode is shown in a bright color M01579 01 Night mode is shown in a dark color Info The ambient light sensor in the combination instrument detects the brightness of the environment Depending on the amount of light detected by the ambient ...

Page 25: ...er additional information about the operating state of the motorcycle When the ignition is switched on all indicator lamps light up briefly Info The malfunction indicator lamp always lights up as long as the engine is not running If the engine is run ning and the malfunction indicator lamp lights up stop taking care not to endanger yourself or other road users in the process and contact an authori...

Page 26: ...en The transmission is in neutral The oil pressure warning lamp lights up red The oil pressure is too low Stop immediately taking care not to endanger yourself or other road users in the process and switch off the engine Alarm system indicator lamp flashes red Status message on the alarm system optional High beam indicator lamp lights up blue The high beam is switched on The general warning lamp l...

Page 27: ...t warning light can be set The shift warning light is always active during the running in phase up to 1 000 km 621 mi The shift warning light can only be deactivated and the values for RPM1 and RPM2 can only be adjusted after this In RPM1 the shift warning light flashes and in RPM2 it flashes and the color changes Info In sixth gear the shift warning light is deactivated when the engine is warm af...

Page 28: ...ngine failure Overheating damages the engine If the coolant temperature warning is displayed stop imme diately and take care not to endanger yourself or other traffic participants in the process Allow the engine and cooling system to cool down Check and if necessary correct the coolant level on the cool ing system while it is in a cooled state Info When all the bars light up the warning ENGINE TEM...

Page 29: ...evel display is next updated after 2 minutes The fuel level display flashes if the combination instrument does not receive a signal from the fuel level sensor 7 13 Time M01581 13 The time is shown in area 1 of the display The time is displayed in 24 hour format in all languages except for EN US The time is displayed in 12 hour format if the language is set to EN US The time can be configured in th...

Page 30: ...selected 7 17 Menu F00906 10 Info Press the SET button 1 in the start screen to open the menu Navigate through the menu using the UP button 2 or the DOWN button 3 Press the BACK button 4 to close the current menu or the menu overview 7 17 1 KTM MY RIDE optional S05079 01 Condition The motorcycle is stationary Function KTM MY RIDE optional activated Function Bluetooth optional activated Press the S...

Page 31: ...n when the menu is closed Press the UP or DOWN button until Settings is highlighted Press the SET button to open the menu Favorites quick selections and the combination instrument display can be configured in Settings Settings can be made for units or various values Several functions can be enabled or disabled 7 17 5 Pairing optional F01958 01 Condition The motorcycle is stationary Function KTM MY...

Page 32: ...ed Press the SET button to open the menu Info Two cellphones can never be paired simultaneously with the combination instrument Press the UP or DOWN button until Pairing is marked Press the SET button to open the menu The combination instrument starts searching for a suitable cellphone If the search was successful the name of the cell phone is displayed in the Pairing menu Press the SET button to ...

Page 33: ... button until Headset is marked Press the SET button to open the menu Press the UP or DOWN button until Pairing is marked Press the SET button to open the menu The combination instrument starts searching for a suitable headset If the search was successful the name of the head set is displayed in the Pairing menu Press the SET button to select the device Press the SET button again to confirm the Co...

Page 34: ...til KTM MY RIDE is marked Press the SET button to open the menu Warning Danger of accidents Headphone volume which is too high distracts attention from traffic activity Always select headphone volume which is low enough for you to still clearly hear acoustic signals Press the UP or DOWN button until Audio is marked Press the SET button to open the menu Press and hold the UP button to increase the ...

Page 35: ...Press the SET button when the menu is closed Press the UP or DOWN button until Trips Data is highlighted Press the SET button to open the menu Press the UP or DOWN button until General Info is highlighted Press the SET button to open the menu Date shows the date ODO displays the total distance covered Battery displays the battery voltage 7 17 11 Trip 1 E01062 01 Press the SET button when the menu ...

Page 36: ...e distance you can cover with the fuel reserve Press and hold the SET button for 3 5 seconds All the entries in the Trip 2 menu are reset 7 17 13 Warning V01167 01 Condition Message or warning is present Press the SET button when the menu is closed Press the UP or DOWN button until Trips Data is highlighted Press the SET button to open the menu Press the UP or DOWN button until Warning is highligh...

Page 37: ... can be selected in the Favourites menu 7 17 16 Quick Selector 1 V01169 01 Condition The motorcycle is stationary Press the SET button when the menu is closed Press the UP or DOWN button until Settings is marked Press the SET button to open the menu Press the UP or DOWN button until Quick Selector 1 is marked Press the SET button to open the menu Press the UP or DOWN button to activate the menu it...

Page 38: ... can only be used in conjunction with KTM MY RIDE optional When the Bluetooth function is switched on and the device is connected the Bluetooth symbol appears in the display of the combination instrument 7 17 19 Display Theme F01957 01 Condition The motorcycle is stationary Press the SET button when the menu is closed Press the UP or DOWN button until Settings is highlighted Press the SET button t...

Page 39: ... RPM 1 the engine speed display lights up red When the engine speed reaches RPM 2 the engine speed display flashes red 7 17 21 Setting the time and date Condition The motorcycle is stationary S05084 01 Press the SET button when the menu is closed Press UP or DOWN button until Settings appears Press the SET button to open the menu Press the UP or DOWN button until Time Date is highlighted Press the...

Page 40: ...s is highlighted Press the SET button to open the menu Press the UP or DOWN button until Units is highlighted Press the SET button to open the menu Press the UP or DOWN button until Distance is marked Press the SET button to open the menu Activate the menu item using the UP or DOWN button Press SET button to confirm the desired unit 7 17 23 Temperature E01064 01 Condition The motorcycle is station...

Page 41: ...he menu Press the UP or DOWN button to activate the menu item and select it with the SET button The menu languages are US English UK English German Italian French and Spanish 7 17 26 Service V01179 01 Condition The motorcycle is stationary Press the SET button when the menu is closed Press the UP or DOWN button until Settings is highlighted Press the SET button to open the menu Press the UP or DOW...

Page 42: ...7 COMBINATION INSTRUMENT 40 Info The current KTM PowerParts and the available software for your vehicle can be found on the KTM website ...

Page 43: ...re tread pattern are fitted to the front and rear wheel Warning Danger of accidents Non approved or non recommended tires and wheels impact the handling character istic Only use tires wheels approved by KTM with the corresponding speed index Warning Danger of accidents New tires have reduced road grip The contact surface on new tires is not yet roughened Run in new tires with moderate riding at al...

Page 44: ... and tank rucksack according to the manufacturer s instructions Warning Danger of accidents The luggage system will be damaged if it is overloaded Read the manufacturer information on maximum payload when mounting cases Warning Danger of accidents Luggage which has slipped impairs visibility If the tail light is covered you are less visible to traffic behind you especially when it is dark Check th...

Page 45: ...PREPARING FOR USE 8 43 Guideline Maximum permissible overall weight 355 kg 783 lb Maximum permissible front axle load 127 kg 280 lb Maximum permissible rear axle load 228 kg 503 lb ...

Page 46: ...le and check the rear mirror setting Check the fuel level 9 2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Caution Danger of accidents Electronic components and saf...

Page 47: ... until the combination instrument function check has finished Do not open the throttle to start Press the starter for a maximum of 5 seconds Wait for a least five seconds before trying again This motorcycle is equipped with a safety starting sys tem You can only start the engine if the transmission is in neutral or if the clutch lever is pulled when a gear is engaged If the side stand is folded ou...

Page 48: ... defensively and with foresight to detect sources of danger as early as possible Warning Danger of accidents Cold tires have reduced road grip Ride the first miles carefully on every journey at moderate speed until the tires reach operating tem perature Warning Danger of accidents New tires have reduced road grip The contact surface on new tires is not yet roughened Run in new tires with moderate ...

Page 49: ...oad surface and weather conditions Particularly in bends do not shift and accelerate very carefully Brake if necessary and close the throttle at the same time in order to shift down Pull clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Switch off the engine if you are likely to be running at idle speed or stationary for a long time If th...

Page 50: ... remove salt from the brake linings and the brake discs Warning Danger of accidents ABS may increase the stopping distance in certain situations Adjust application of the brakes to the respective riding situation and riding surface conditions When braking release the throttle and apply the front and rear brakes at the same time Info When the ABS is enabled maximum braking power can be achieved eve...

Page 51: ... stand Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk Do not park the vehicle near to materials which are highly flammable or explosive Allow the vehicle to cool down before covering it Apply the brakes on the motorcycle Shift the transmission into neutral Switch off the ignition by turning the ignition key to the position Info If the engine is switched off with the ...

Page 52: ...h hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Note Material damage Inadequate fuel quality causes t...

Page 53: ... of the fuel filler Total fuel tank capacity approx 13 5 l 3 57 US gal Super unleaded ROZ 95 p 119 EU AU JP AR CN CO MY PH 390 DUKE B D 3 EU Total fuel tank capacity approx Gasohol 95 E20 RON 95 p 119 390 DUKE TH Total fuel tank capacity approx Super unleaded type C ROZ 95 RON 95 PON 91 p 119 390 DUKE BR Close the fuel tank filler cap p 19 ...

Page 54: ...ke discs p 67 Check the front brake linings p 69 Check the rear brake linings p 73 Check the brake lines for damage and leakage Check the front brake fluid level p 67 Check the rear brake fluid level p 71 Check the tire condition p 78 Check tire pressure p 80 Check the shock absorber and fork for leaks Clean the dust boots of the fork legs p 57 Check the chain rear sprocket and engine sprocket p 6...

Page 55: ...er 1 000 km 620 mi Check the frame Check the link fork Checking the fork bearing for play Check the wheel bearing for play Check the antifreeze Change the coolant p 95 Empty the drainage hoses Check all hoses e g fuel coolant bleeder drainage etc and sleeves for cracking leaks and incorrect routing Grease all moving parts e g side stand hand lever chain and check for smooth operation Check the tig...

Page 56: ...ensuring an ideal compromise between handling and stability S04743 10 Adjust the spring preload by turning adjusting ring 1 Guideline Spring preload Standard 5 clicks Hook wrench shock absorber 90529077000 Extension for hook wrench 90129099025 Info The spring preload can be set to 10 different positions 11 2 Adjusting the shift lever Info The adjustment range of the shift lever is limited S04744 1...

Page 57: ...s have been tightened the bearings of the shift rod must be central and aligned identically to each other in order to ensure freedom of movement in the bearing shells Check the shift lever to ensure it is functioning properly and can move freely ...

Page 58: ... adapters and raise the motorcycle 12 2 Removing the rear of the motorcycle from the lifting gear Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 402029 10 Secure the motorcycle against falling over Remove the rear lifting gear and lean the vehicle on side stand 1 Remove bushings kit 12 3 Lifting the motorcycle with the front lifting...

Page 59: ...e front lifting gear Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 402777 01 Main work Secure the motorcycle against falling over Remove the front lifting gear F00795 10 Mount protection cap 1 Finishing work Remove the rear of the motorcycle from the lifting gear p 56 12 5 Cleaning the dust boots of the fork legs Preparatory work R...

Page 60: ... dust boots and inside fork tubes of both fork legs Universal oil spray p 120 Press the dust boots back into the installation position Remove the excess oil Finishing work Take the motorcycle off the front lifting gear p 57 Remove the rear of the motorcycle from the lifting gear p 56 12 6 Removing the passenger seat H01991 10 Insert the ignition key in seat lock 1 and turn it clockwise Raise the r...

Page 61: ...atory work Remove the passenger seat p 58 H01993 01 Main work Raise the rear of the front rider s seat pull it towards the rear and remove it upwards 12 9 Mounting the front rider s seat H01994 01 Main work Attach the front rider s seat in area A and lower at the rear Finally check that the front rider s seat is correctly mounted Finishing work Mount the passenger seat p 58 12 10 Checking for chai...

Page 62: ...fting gear p 56 400725 01 Main work Clean the chain regularly Rinse off the loose dirt with a gentle jet of water Remove grease residue with chain cleaner Chain cleaner p 120 After drying apply chain spray Street chain spray p 120 Finishing work Remove the rear of the motorcycle from the lifting gear p 56 12 12 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages ...

Page 63: ...rear wheel bearings wear more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Raise the motorcycle with the rear lifting gear p 56 Check ...

Page 64: ...in kit Info The engine sprocket rear sprocket and chain should always be replaced together 401288 10 Shift the transmission into neutral Pull on the lower chain section with the specified weight A Guideline Weight chain wear measure ment 15 kg 33 lb Measure distance B of 20 chain rollers in the lower chain section Info Chain wear is not always even so you should repeat this measurement at differen...

Page 65: ...n sliding guard is loose Tighten the screw of the chain sliding guard Guideline Screw chain guard M5 7 Nm 5 2 lbf ft Loctite 243 Finishing work Remove the rear of the motorcycle from the lifting gear p 56 12 15 Adjusting the basic position of the clutch lever F00783 11 Adjust the basic position of the clutch lever to your hand size by turning adjusting wheel 1 Info Push the clutch lever forward an...

Page 66: ...12 SERVICE WORK ON THE CHASSIS 64 12 16 Removing the front spoiler S04745 10 Remove screws 1 and remove the front spoiler S04746 10 Remove screws 2 Remove lower part of front spoiler ...

Page 67: ...ler S04746 11 Position the lower part of front spoiler Mount and tighten screws 1 Guideline Screw front spoiler lower part M6x14 9 Nm 6 6 lbf ft S04745 11 Position the front spoiler mount and tighten screws 2 Guideline Screw front spoiler M6x12 9 Nm 6 6 lbf ft ...

Page 68: ...ing road surfaces steep descents or full braking without disengaging the gear Adapt your riding style to the road conditions and your driving ability The ABS operates with two independent brake circuits front and rear brakes During normal operation the brake system operates like a conventional brake system without ABS When the ABS con trol unit detects a locking tendency in a wheel ABS begins reg ...

Page 69: ...he thickness of the brake disc at con tact surface 1 of the brake linings Brake discs wear limit front 4 5 mm 0 177 in rear 3 6 mm 0 142 in If the brake disc thickness is less than the specified value Change the front brake disc Change the rear brake disc Check the front and rear brake discs for damage cracking and deformation If the brake disc exhibits damage cracking or deforma tion Change the f...

Page 70: ...ear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brak...

Page 71: ...Worn out brake linings reduce the braking effect Ensure that worn out brake linings are replaced immediately Your authorized KTM workshop will be glad to help Warning Danger of accidents Damaged brake discs reduce the braking effect If the brake linings are not changed in time the brake lining carriers grind against the brake disc As a consequence the braking effect is greatly reduced and the brak...

Page 72: ...forth between the end stop and the contact to the foot brake cylinder piston and check free travel A Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the free travel of the foot brake lever p 70 Reconnect spring 1 13 8 Adjusting the free travel of the foot brake lever Warning Danger of accidents The brake system fails in the event ...

Page 73: ...level drops below the MIN marking the brake system is leaking or the brake linings are worn down Check the brake system and do not continue riding until the problem is eliminated Your authorized KTM workshop will be glad to help Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service sc...

Page 74: ...with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your authorized KTM workshop will be glad to help Note Environmental...

Page 75: ...orn out brake linings reduce the braking effect Ensure that worn out brake linings are replaced immediately Your authorized KTM workshop will be glad to help Warning Danger of accidents Damaged brake discs reduce the braking effect If the brake linings are not changed in time the brake lining carriers grind against the brake disc As a consequence the braking effect is greatly reduced and the brake...

Page 76: ...effect Always lay the wheel down in such a way that the brake disc is not damaged Hold the front wheel and remove the wheel spindle Take the front wheel out of the fork Info Do not actuate the hand brake lever when the front wheel is removed 14 2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oi...

Page 77: ...m 5 9 lbf ft Mount and tighten screws 5 with the washers Guideline Screw front fender M6 7 Nm 5 2 lbf ft Operate the hand brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point Take the motorcycle off the front lifting gear p 57 Remove the rear of the motorcycle from the lifting gear p 56 Operate the front brake and compress the fork a few ...

Page 78: ...ar wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Warning Danger of accidents There is no braking effect to start with at the rear brake after installing the rear wheel Actuate the foot brake several times before going on a ride until you can fee...

Page 79: ... the washer Push the rear wheel forward so that the chain adjusters are in contact with the screws and tighten nut 2 Guideline In order for the rear wheel to be correctly aligned the mark ings on the left and right chain adjusters must be in the same position relative to reference markings B Nut rear wheel spin dle M14x1 5 98 Nm 72 3 lbf ft Position wheel speed sensor 5 in the hole Mount and tight...

Page 80: ...or worn Change all the damping rubber pieces of the rear hub F00869 10 Lay the rear wheel on a workbench with the rear sprocket fac ing upward and insert the wheel spindle in the hub To check play A hold the rear wheel tight and try to rotate the rear sprocket Info Measure the play on the outside of the rear sprocket Play of damping rubber pieces on rear wheel 5 mm 0 2 in If clearance A is larger ...

Page 81: ...s have a negative effect on handling characteristics especially on wet surfaces 400602 10 Check the front and rear tires for cuts run in objects and other damage If the tires have cuts run in objects or other damage Change the tires Check the tread depth Info Observe the minimum tread depth required by national law Minimum tread depth 2 mm 0 08 in If the tread depth is less than the minimum tread ...

Page 82: ...omfort and maximum tire service life 400695 01 Remove the protection cap Check the tire pressure when the tires are cold Tire pressure when solo front 2 0 bar 29 psi rear 2 0 bar 29 psi Tire pressure with passenger full payload front 2 0 bar 29 psi rear 2 2 bar 32 psi If the tire pressure does not meet specifications Correct the tire pressure Mount the protection cap ...

Page 83: ...nning light DRL must only be switched on when visibility conditions are good The daytime running light DRL function can be activated and deactivated by an authorized KTM dealer This is controlled by the ambient light sensor in the combination instrument When visibility conditions are good the low beam is switched off and the daytime running light is switched on Info The position light 1 lights up ...

Page 84: ...t a 12 V battery In both cases elec trical components and safety devices can be damaged The vehicle will therefore no longer be roadworthy 15 3 Installing the 12 V battery V01274 11 Main work Position the 12 V battery in the battery compartment 12 V battery ETZ 9 BS p 112 Attach rubber strap 1 Position positive cable 2 and mount and tighten the screw Position positive terminal cover 3 V01273 11 Po...

Page 85: ...s at a collection point for used batteries Info Even when there is no load on the 12 V battery it discharges steadily each day The charging level and the method of charging are very important for the service life of the 12 V battery Rapid recharging with a high charging current shortens the service life of the battery If the charging current charging voltage or charging time is exceeded electrolyt...

Page 86: ...ect from the 12 V battery Guideline The charging current charging voltage and charging time must not be exceeded Recharge the 12 V battery regularly when the motorcy cle is not being used 3 months Position the negative cable and mount and tighten the screw Position the negative terminal cover Finishing work Mount the front rider s seat p 59 Mount the passenger seat p 58 Set time and date p 37 15 5...

Page 87: ...nishing work Mount the passenger seat p 58 Set time and date p 37 15 6 Changing the ABS fuses Warning Fire hazard Incorrect fuses overload the electrical system Only use fuses with the required ampere value Do not bypass or repair fuses Info Two fuses for the ABS are located under the passenger seat These fuses protect the return pump and the hydraulic unit of the ABS The third fuse which protects...

Page 88: ...ert spare fuse 2 in the fuse box so that it is available if needed Mount the protection cap S04756 11 To change the fuse of the ABS return pump Take off the protection cap and remove fuse 3 Info A faulty fuse has a burned out fuse wire A Warning Fire hazard Incorrect fuses overload the electrical system Only use fuses with the required ampere value Do not bypass or repair fuses Insert the spare fu...

Page 89: ...1 30 A main fuse Fuse 2 10 A combination instrument Fuse 3 10 A power relay Fuse 4 15 A ignition coil fuel pump start auxiliary relay horn Fuse 5 15 A radiator fan Fuse 6 15 A brake light turn signal high beam low beam position light tail light license plate lamp Fuse 7 10 A engine control unit ABS control unit Fuse 8 10 A alarm system optional Fuse 9 10 A permanent positive for auxiliary equip me...

Page 90: ...iliary equip ment ACC1 Fuse 10 10 A ignition positive for auxiliary equipment ACC2 Fuse SPARE 10 A 15 A 30 A spare fuses Info A faulty fuse has a burned out fuse wire A Warning Fire hazard Incorrect fuses overload the electrical system Only use fuses with the required ampere value Do not bypass or repair fuses Insert the spare fuse with the correct rating Fuse 75011088010 p 112 Fuse 75011088015 p ...

Page 91: ...to be operated with the rider mounted along with any luggage and a passenger if applicable If the boundary between light and dark does not meet specifications Adjust the headlight range p 89 15 9 Adjusting the headlight range Preparatory work Check the headlight setting p 89 F00850 10 Main work Turn adjusting screw 1 to adjust the headlight range Info Turn clockwise to increase the headlight range...

Page 92: ... the passenger seat 15 11 Front ACC1 and ACC2 E01189 10 Installation location Power supplies ACC1 1 and ACC2 2 front are located on the left of the vehicle behind the cover under the fuel tank 15 12 ACC2 rear S04730 10 Installation location Rear ACC2 1 power supplies are located under the passenger seat ...

Page 93: ... 2 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature Allow the cooling system and the engine to cool down before you open the radiator the radiator hoses or othe...

Page 94: ...ci fied value Correct the antifreeze in the coolant Check the coolant level in the radiator The radiator must be filled completely If the coolant level does not match the specified value Check the coolant level and the reason for the loss Coolant p 118 If you had to add more coolant than the specified amount 0 20 l 0 21 qt Fill bleed the cooling system p 94 Mount the radiator cap 16 3 Checking the...

Page 95: ... not match the specified value Correct the coolant level Coolant p 118 F00856 11 Remove radiator cap 2 and check the coolant level in the radiator The radiator must be filled completely If the coolant level does not match the specified value Check the coolant level and the reason for the loss If you had to add more coolant than the specified amount 0 20 l 0 21 qt Fill bleed the cooling system p 94...

Page 96: ...e upright Position an appropriate container under the engine Remove screw 1 with the seal ring Remove the radiator cap Completely drain the coolant Mount and tighten screw 1 with a new seal ring Guideline Screw plug water pump drain hole M6 10 Nm 7 4 lbf ft 16 5 Filling bleeding the cooling system Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of chi...

Page 97: ...engine and allow it to warm up F00855 11 Stop the engine and allow it to cool down When the engine is cool check the coolant level in the radiator and if necessary add coolant Remove cap 3 of the compensating tank and top up the coolant level to the upper marking Mount the cap of the compensating tank Finishing work Fit the front spoiler p 65 16 6 Changing the coolant Warning Danger of scalding Du...

Page 98: ...on The engine is cold Preparatory work Remove the front spoiler p 64 S04750 10 Main work Position the motorcycle upright Position an appropriate container under the engine Remove screw 1 with the seal ring F00856 11 Remove radiator cap 2 Completely drain the coolant Mount and tighten screw 1 with a new seal ring Guideline Screw plug water pump drain hole M6 10 Nm 7 4 lbf ft F00870 11 Loosen bleede...

Page 99: ...t extraction when starting or running the engine in an enclosed space Start the engine and allow it to warm up F00855 12 Stop the engine and allow it to cool down When the engine is cool check the coolant level in the radiator and if necessary add coolant Remove cap 4 of the compensating tank and top up the coolant level up to the MAX marking Mount the cap of the compensating tank Finishing work F...

Page 100: ...sistance is perceptible and deter mine the play in the clutch lever A Clutch lever play A 1 3 mm 0 04 0 12 in If the clutch lever play does not meet the specified value Adjust play in the clutch lever p 98 Move the handlebar to and fro over the entire steering range The clutch lever play must not change If the clutch lever play changes Check the routing of the clutch cable 17 2 Adjusting play in t...

Page 101: ...the engine oil level 18 2 Changing the engine oil and oil filter cleaning the oil screens Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden Wear suitable protective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Note Environmental hazard Hazardous substances cause environmental damage Dispose of oi...

Page 102: ...reen screw plug small M17x1 5 12 Nm 8 9 lbf ft S04748 10 Remove screws 5 Take off oil filter cover 6 with the O ring Pull oil filter 7 out of the oil filter housing Allow the engine oil to drain completely Thoroughly clean the parts and the sealing surface S04749 10 Insert new oil filter 7 Oil the O ring of the oil filter cover Mount oil filter cover 6 Mount and tighten the screws Guideline Screw ...

Page 103: ...t in premature wear of the engine 401955 10 Main work Remove filler plug 1 with the O ring and fill up with engine oil Engine oil SAE 15W 50 p 118 Info In order to achieve optimal engine oil performance it is not advisable to mix different engine oils KTM recommends changing the engine oil Mount and tighten the filler plug together with the O ring Danger Danger of poisoning Exhaust gases are toxic...

Page 104: ...rect sunshine when cleaning the motorcycle 401061 01 Close off exhaust system to keep water from entering Remove loose dirt first with a soft jet of water Spray the heavily soiled parts with a normal commercial motor cycle cleaner and clean using a brush Motorcycle cleaner p 120 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry motor...

Page 105: ... surfaces p 120 Lubricate the ignition and steering lock Universal oil spray p 120 19 2 Checks and maintenance steps for winter operation Info If you use the motorcycle in winter you must expect salt on the roads You should therefore take precau tions against aggressive road salt Clean the motorcycle with cold water if it has been used on salted roads Warm water enhances the corro sive effects of ...

Page 106: ...l screens p 99 Check the antifreeze and coolant level p 91 Check tire pressure p 80 Remove the 12 V battery p 81 Charge the 12 V battery p 83 Guideline Storage temperature of the 12 V battery without direct sunlight 0 35 C 32 95 F Store vehicle in a dry location that is not subject to large fluc tuations in temperature Info KTM recommends jacking up the motorcycle Raise the motorcycle with the rea...

Page 107: ...059 01 Take the motorcycle off the front lifting gear p 57 Remove the rear of the motorcycle from the lifting gear p 56 Install the 12 V battery p 82 Set time and date p 37 Perform checks and maintenance measures when preparing for use p 44 Take a test ride ...

Page 108: ...oling system p 94 Thermostat defective Check the thermostat Fuse 5 blown Change the fuses of individual electri cal power consumers p 87 Defect in radiator fan system Check the radiator fan system Malfunction indicator lamp lights up yellow Malfunction in the electronic fuel injection Read out the fault memory using the KTM diagnostics tool Engine dies during the trip Lack of fuel Refuel p 50 Fuse...

Page 109: ...charged by the alternator Check the charging voltage Check the open circuit current The combination instrument shows nothing on the display Fuse 2 is blown Change the fuses of individual electri cal power consumers p 87 Speedometer in combination instrument not functioning Speedometer wiring harness is damaged or plug in connector is oxidized Check the wiring harness and plug in connector ...

Page 110: ...rings 1 compression ring 1 tapered compression piston ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with 2 trochoidal pumps Primary transmission 30 80 Clutch Slipper clutch in oil bath mechanically operated Transmission 6 gear transmission claw shifted Transmission ratio 1st gear 12 32 2nd gear 14 26 3rd gear 19 27 4th gear 21 24 5th gear 23 22 6th gear 25 21 Mixture ...

Page 111: ...ing support M6 10 Nm 7 4 lbf ft Screw camshaft decompression shaft M6 10 Nm 7 4 lbf ft Loctite 243 Screw chain securing guide M6 10 Nm 7 4 lbf ft Loctite 243 Screw clutch cable retaining bracket M6 6 Nm 4 4 lbf ft Loctite 243 Screw clutch cover M6 12 Nm 8 9 lbf ft Screw clutch spring M6 10 Nm 7 4 lbf ft Screw engine case M6x35 12 Nm 8 9 lbf ft Screw engine case M6x75 12 Nm 8 9 lbf ft Loctite 243 S...

Page 112: ...ange M8 22 Nm 16 2 lbf ft Screw conrod bearing M8 5x0 75 15 Nm 11 1 lbf ft 75 Coolant temperature sensor M10 14 Nm 10 3 lbf ft Oil pressure sensor M10 14 Nm 10 3 lbf ft Screw camshaft gear wheel M10 36 Nm 26 6 lbf ft Loctite 243 Screw cylinder head M10 1st stage 30 Nm 22 1 lbf ft 2nd stage 60 Nm 44 3 lbf ft Thread is oiled head flat is greased Screw rotor M10 105 Nm 77 4 lbf ft Loctite 243 Screw p...

Page 113: ... Gasohol 95 E20 RON 95 p 119 390 DUKE TH Total fuel tank capacity approx Super unleaded type C ROZ 95 RON 95 PON 91 p 119 390 DUKE BR Fuel reserve approx 1 5 l 1 6 qt 22 4 Chassis Frame Lattice frame of steel tubes powder coated Fork WP Suspension Shock absorber WP Suspension Brake system front Disc brake with 4 piston brake caliper rear Disc brake with single pot brake caliper floating Suspension...

Page 114: ...783 lb 22 5 Electrical system 12 V battery ETZ 9 BS Battery voltage 12 V Nominal capacity 8 Ah Maintenance free Fuse 75011088010 10 A Fuse 75011088015 15 A Fuse 90111088025 25 A Fuse 75011088030 30 A Headlight LED Position light LED Combination instrument lighting and indicator lamps LED Turn signal LED Brake tail light LED License plate lamp LED 22 6 Tires Front tire Rear tire 110 70 R 17 M C 54H...

Page 115: ... 243 Screw compensating tank cap lock rear brake M5 9 Nm 6 6 lbf ft Screw fuel tank cover M5 4 Nm 3 lbf ft Screw outer clutch cable guide M5 5 Nm 3 7 lbf ft Loctite 243 Screw side stand sensor M5 5 Nm 3 7 lbf ft Loctite 243 Screw tail light M5 5 Nm 3 7 lbf ft Nut foot brake lever adjustment M6 9 Nm 6 6 lbf ft Remaining nuts chassis M6 10 Nm 7 4 lbf ft Remaining screws chassis M6 10 Nm 7 4 lbf ft S...

Page 116: ...3 7 lbf ft Loctite 243 Screw main silencer M6 12 Nm 8 9 lbf ft Screw main silencer retaining bracket M6 9 Nm 6 6 lbf ft Screw protective plate M6 8 Nm 5 9 lbf ft Screw radiator holder M6 10 Nm 7 4 lbf ft Screw radiator shield M6 7 Nm 5 2 lbf ft Screw rear splash protector M6 9 Nm 6 6 lbf ft Screw rear wheel speed sensor M6 8 Nm 5 9 lbf ft Loctite 243 Screw shift lever linkage M6 11 Nm 8 1 lbf ft L...

Page 117: ...2 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw engine bearer M10 49 Nm 36 1 lbf ft Loctite 243 Fitting handlebar support M10x1 25 21 Nm 15 5 lbf ft Fitting shock absorber bottom M10x1 25 51 Nm 37 6 lbf ft Loctite 243 Nut left rear mirror M10x1 25 16 Nm 11 8 lbf ft Nut right rear mirror M10LHx1 25 16 Nm 11 8 lbf ft Nut side stand bracket M10x1 25 35 Nm 25 8 lbf ft Screw combination i...

Page 118: ...22 TECHNICAL DATA 116 Nut steering head M30x1 1st stage 45 Nm 33 2 lbf ft 2nd stage loosen counterclock wise 2 turns 3rd stage 5 Nm 3 7 lbf ft ...

Page 119: ...wireless system conforms with the relevant guidelines The full text of the Declaration of Conformity is available at the following Internet address Certification website http www ktm com btrouter JNS Instruments Ltd hereby declares that the 210M1100 wireless system conforms with the relevant guidelines The full text of the Declaration of Conformity is available at the following Internet address Ce...

Page 120: ...s Only use coolant that complies with the requirements stated see specifications on the container and that has the relevant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications f...

Page 121: ...ol e g E30 E85 E100 Super unleaded ROZ 95 Standard classification DIN EN 228 ROZ 95 Guideline Only use super unleaded fuel that matches or is equivalent to the specified standard Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 Super unleaded type C ROZ 95 RON 95 PON 91 Standard c...

Page 122: ...o Clean Perfect finish and high gloss polish for paints Recommended supplier MOTOREX Moto Shine Preserving materials for paints metal and rubber Recommended supplier MOTOREX Moto Protect Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Street chain spray Guideline Recommended supplier MOTOREX Chainlube Road Strong Universal o...

Page 123: ...ice intervals are demanded for automobile engines the focus for motorcycle engines is on high performance at high engine speeds In most motorcycle engines the transmission and clutch are lubricated with the same oil The JASO T903 MA2 standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils accordin...

Page 124: ...time Running Light Light which enhances the visibility of the vehicle dur ing the day but is not focused and in contrast to low beam does not illuminate the road surface KTM MY RIDE System for wireless communication with appropriate cellphones and headsets for telephony and audio OBD On board diagnosis Vehicle system which monitors the specified parame ters of the vehicle electronics ...

Page 125: ...LIST OF ABBREVIATIONS 28 123 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 126: ...up yellow The OBD has detected a malfunction in the vehi cle electronics Come safely to a halt and contact an authorized KTM workshop The ABS warning lamp lights up yellow Status or error messages relating to ABS The ABS warning lamp flashes if the ABS mode Super Moto is enabled The general warning lamp lights up yellow A note warning note on operating safety has been detected This is shown in add...

Page 127: ...ever 15 basic position adjusting 63 Clutch lever play checking 98 Combination instrument 22 40 ABS 34 activation and test 22 Audio 32 Bluetooth optional 36 Consumption 39 coolant temperature indicator 26 day night mode 22 display 24 Display Theme 36 Distance 38 Extra Functions 39 Favourites 35 Favourites display 27 fuel level display 27 General Info 33 Headset 31 indicator lamps 23 KTM MY RIDE 28 ...

Page 128: ...Fuse for individual electrical power consumers changing 87 G Grab handles 20 H Hand brake lever 15 basic position adjusting 67 Headlight daytime running light 81 range adjusting 89 Headlight setting checking 89 Horn button 16 I Ignition lock 17 Implied warranty 10 Indicator lamps 23 K Key number 14 L Light switch 16 Loading the vehicle 42 Luggage 42 M Main fuse changing 84 Manufacturer warranty 10...

Page 129: ...Steering lock 17 Stopping 49 Storage 104 Switch on the left side of the handlebar 15 on the right side of the handlebar 17 T Technical accessories 10 Technical data capacities 111 chassis 111 chassis tightening torques 113 electrical system 112 engine 108 engine tightening torques 109 fork 113 shock absorber 113 tires 112 Throttle grip 15 Time adjusting 37 Tire condition checking 78 Tire pressure ...

Page 130: ... 3214321en 3214321en 09 2021 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria KTM COM Photo Mitterbauer KISKA KTM ...

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KTM F4303U1, Owner'S Manual

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