KTM Freeride 250 F 2018 Page 86 Owner'S Manual Download | Manualshive

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13 BRAKE SYSTEM

84

13.1

Checking the free travel of the hand brake lever

Warning

Danger of accidents

The brake system fails in the event of overheating.

If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit.

–

Set the free travel on the hand brake lever in accordance with the specification.

E01007-11

–

Push the hand brake to the handlebar and check free
travel

A

.

Free travel of hand brake
lever

≥

3 mm (

≥

0.12 in)

» If the free travel does not meet specifications:

–

Adjust the free travel of the handbrake lever. (

13.2

Adjusting the free travel of the handbrake lever

E01007-10

–

Check the free travel of the hand brake lever. (

–

Adjust the free travel of the handbrake lever with adjustment
screw

1

.

Info

Turn the adjusting screw clockwise to reduce free
travel. The pressure point moves away from the
handlebar.
Turn the adjusting screw counterclockwise to increase
free travel. The pressure point moves towards the han-
dlebar.
The range of adjustment is limited.
Only turn the adjusting screw by hand, and do not use
force.
Do not make any adjustments while riding.

13.3

Checking the brake discs

Warning

Danger of accidents

Worn-out brake discs reduce the braking effect.

–

Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will
be glad to help.)

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Summary of Contents for Freeride 250 F 2018

Page 1: ...OWNER S MANUAL 2018 Freeride 250 F Art no 3213652en ...

Page 2: ......

Page 3: ... forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for delivery options deviations from figures and descriptions misprints and other errors The models portrayed partly contain special equipment that does not belong to ...

Page 4: ... 16 Foot brake lever 20 6 17 Side stand 20 6 18 Ignition lock 20 6 19 Steering lock 21 6 20 Locking the steering 21 6 21 Unlocking the steering 21 7 COMBINATION INSTRUMENT 22 7 1 Combination instrument overview 22 7 2 Activation and test 22 7 3 Adjusting the kilometers or miles 22 7 4 Adjusting the combination instrument 23 7 5 Adjusting the clock 24 7 6 Viewing the lap time 24 7 7 Display mode SP...

Page 5: ... 60 12 12 Adjusting the play of the steering head bearing 61 12 13 Greasing the steering head bearing 61 12 14 Removing front fender 61 12 15 Installing front fender 62 12 16 Removing the shock absorber 63 12 17 Installing the shock absorber 63 12 18 Folding the seat up 64 12 19 Locking the seat 64 12 20 Taking off the spoiler 64 12 21 Mounting the spoiler 65 12 22 Removing the air filter housing ...

Page 6: ...ing the antifreeze and coolant level 112 16 3 Checking the coolant level 113 16 4 Draining the coolant 114 16 5 Refilling coolant 115 17 TUNING THE ENGINE 116 17 1 Checking the play in the throttle cable 116 17 2 Adjusting the play in the throttle cable 116 17 3 Adjusting the characteristic map of the throttle response 117 17 4 Adjusting the idle speed 118 17 5 Teaching the throttle valve position...

Page 7: ...ared for there by specially trained experts using the auxiliary tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a testing step Indicates the end of an activity including potential reworking 1 2 Formats used The typographical formats used in this document are explained below Propriet...

Page 8: ...ed to operate the model described safely Therefore read this instruction and all further instructions included carefully The safety instructions are highlighted in the text and are referred to at the relevant passages Info Various information and warning labels are attached in prominent locations on the model described Do not remove any information or warning labels If they are missing you or othe...

Page 9: ...ion Danger 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 ...

Page 10: ...onflicts do not occur To protect the future of the motorcycle sport make sure that you use your motorcycle legally display environmental conscious ness and respect the rights of others When disposing of used oil other operating and auxiliary fluids and used components comply with the laws and regulations of the respective country Because motorcycles are not subject to the EU regulations governing ...

Page 11: ...ur authorized KTM dealer will be glad to advise you The current KTM PowerParts for your vehicle can be found on the KTM website International KTM Website http www ktm com 3 4 Service 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 Incorrect adjustment ...

Page 12: ...3 IMPORTANT NOTES 10 A list of authorized KTM dealers can be found on the KTM website International KTM Website http www ktm com ...

Page 13: ... OF VEHICLE 4 11 4 1 View of vehicle front left example H02567 10 1 Hand brake lever p 15 2 Clutch lever p 15 3 Filler cap 4 Seat release 5 Side stand p 20 6 Battery 7 Shift lever p 19 8 Steering lock p 21 ...

Page 14: ...witch p 15 1 Horn button p 16 1 Light switch p 16 1 Turn signal switch p 16 2 Emergency OFF switch p 16 3 Electric starter button p 17 4 Throttle grip p 15 5 Chassis number p 13 5 Type label p 13 6 Fork part number p 14 7 Foot brake lever p 20 8 Level viewer for brake fluid rear ...

Page 15: ...946 10 Type label 1 is fixed to the front of the steering head 5 3 Key number H02562 10 The key number 1 can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place 5 4 Engine number H01047 10 The engine number 1 is embossed on the left side of the engine above the engine sprocket ...

Page 16: ...1947 10 The fork part number 1 is stamped on the inner side of the axle clamp 5 6 Shock absorber article number H02222 10 Shock absorber article number 1 is stamped on the top of the shock absorber above the adjusting ring towards the motor side ...

Page 17: ...e is engaged using the hand brake lever 6 3 Throttle grip F01171 10 The throttle grip 1 is fitted on the right side of the handlebar 6 4 Kill switch F01183 10 Kill switch 1 is fitted on the left side of the handlebar Possible states Kill switch in basic position In this position the ignition circuit is closed and the engine can be started Kill switch pressed In this position the ignition circuit i...

Page 18: ...e high beam and the tail light are switched on 6 7 Turn signal switch F01183 12 Turn signal switch 1 is fitted on the left side of the handlebar Possible states Turn signal light off Turn signal switch is in the cen tral position Turn signal light left on Turn signal switch is turned to the left Turn signal light right on Turn signal switch is turned to the right 6 8 Emergency OFF switch F01172 10...

Page 19: ...able The fuel in the fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes 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 poisonou...

Page 20: ...dy The injection system extends the injection time if the engine is cold and the outside temperature is low To help the engine burn the increased amount of fuel it must be supplied with additional oxygen by pushing the cold start button After briefly opening up the throttle and then releasing the throttle grip again or turning the throttle grip towards the front the cold start button returns to it...

Page 21: ... than an engine with the idle speed set incorrectly The idle speed is adjusted using the idle speed adjusting screw 1 Increase the idle speed by turning the idle speed adjusting screw clockwise Decrease the idle speed by turning the idle speed adjusting screw counterclockwise 6 15 Shift lever 401950 10 Shift lever 1 is mounted on the left side of the engine 401950 11 The gear positions can be seen...

Page 22: ...The side stand is used for parking the motorcycle Info When you are riding side stand 1 must be folded up and secured with rubber band 2 6 18 Ignition lock F01214 10 The ignition lock 1 is on the right behind the headlight mask Possible states Ignition off In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start Ignition on In this positio...

Page 23: ...732 01 Park the vehicle Turn the handlebar as far as possible to the right Grease steering lock regularly Universal oil spray p 147 Insert the key in the steering lock p 21 turn it to the left press it in and turn it to the right Remove the key Steering is no longer possible Info Never leave the key in the steering lock 6 21 Unlocking the steering 400731 01 Insert the key in the steering lock p 21...

Page 24: ...el size After the display function check the wheel circumference WS is displayed briefly Info The number 2205 equals the circumference of the 21 front wheel with standard tires The display then changes to the last selected mode 7 3 Adjusting the kilometers or miles Info If you change the unit the value ODO is retained and converted accordingly The values TR1 TR2 A1 A2 and S1 are cleared when the u...

Page 25: ... right of the display Press the button for 2 3 seconds The Setup menu is displayed and the active functions are shown Info If no button is pressed for 10 12 seconds the settings are automatically saved If no button is pressed for 20 seconds or if an impulse comes from the wheel speed sensor the settings are automatically saved and the setup menu is closed Repeatedly press the button briefly until ...

Page 26: ...on is pressed for 15 20 seconds or if an impulse comes from the wheel speed sensor the settings are automatically saved and the setup menu is closed 7 6 Viewing the lap time Info This function can only be opened if lap times have actually been timed Condition The motorcycle is stationary 400321 01 Repeatedly press the button briefly until LAP appears at the bottom right of the display Briefly pres...

Page 27: ...mode H the service hours of the engine are displayed The service hour counter stores the total traveling time Info The service hour counter is necessary for ensuring that service work is carried out at the right intervals If the combination instrument is in H display mode when starting off it automatically changes to the ODO display mode The H display mode is suppressed during the journey Press th...

Page 28: ... changes to H or ODO 7 10 Adjusting the unit of measurement 400329 01 Condition The motorcycle is stationary Repeatedly press the button briefly until H appears at the bottom right of the display Press the button for 2 3 seconds Repeatedly press the button briefly until Km h Mph flashes In measurement unit mode you can change the unit of measure ment Info If no button is pressed for 5 seconds the ...

Page 29: ...fly until CLK appears at the bottom right of the display Press the button for 2 3 seconds Press the but ton for 2 3 seconds Increases the value Briefly press the button Increases the value Press the but ton for 2 3 seconds Reduces the value Briefly press the button Reduces the value Wait 3 5 seconds Changes to the next value Wait 10 12 seconds Closes the SETUP menu 7 13 Display mode SPEED LAP lap ...

Page 30: ...AP appears at the bottom right of the display Briefly press the button Press the but ton for 2 3 seconds The stop watch and the lap time are reset Briefly press the button Select a lap from 1 10 Press the but ton for 2 3 seconds No function Briefly press the button View the next lap time 7 15 Display mode SPEED ODO odometer 400317 01 Repeatedly press the button briefly until ODO appears at the bot...

Page 31: ...ction Briefly press the button No function 7 17 Display mode SPEED TR2 trip master 2 400324 01 Repeatedly press the button briefly until TR2 appears at the top right of the display TR2 trip master 2 runs constantly and counts up to 999 9 Press the but ton for 2 3 seconds Clears the values TR2 and A2 Briefly press the button Next display mode Press the but ton for 2 3 seconds Reduces value of TR2 B...

Page 32: ...ws the average speed calculated using TR1 trip master 1 and S1 stop watch 1 The calculation of this value is activated by the first impulse of the wheel speed sensor and ends 3 seconds after the last impulse Press the but ton for 2 3 seconds Displays of TR1 A1 and S1 are reset to 0 0 Briefly press the button Next display mode Press the but ton for 2 3 seconds No function Briefly press the button N...

Page 33: ...l speed sensor and ends 3 seconds after the last impulse Press the but ton for 2 3 seconds Displays of TR1 A1 and S1 are reset to 0 0 Briefly press the button Next display mode Press the but ton for 2 3 seconds No function Briefly press the button No function 7 22 Display mode SPEED S2 stop watch 2 400328 01 Repeatedly press the button briefly until S2 appears at the top right of the display S2 St...

Page 34: ...to the Setup menu Stores and closes the Setup menu Display mode SPEED CLK time The display changes to the Setup menu of the clock Next display mode No function No function Adjusting the clock Increases the value Increases the value Reduces the value Reduces the value Changes to the next value Closes the SETUP menu Display mode SPEED LAP lap time The stop watch and the lap time are reset Next displ...

Page 35: ...on Display mode SPEED S1 stop watch 1 Displays of TR1 A1 and S1 are reset to 0 0 Next display mode No function No function Display mode SPEED S2 stop watch 2 The displays of S2 and A2 are set to 0 0 Next display mode No function Starts or stops S2 7 24 Table of conditions and menu activation Display The motorcycle is stationary Menu can be acti vated Display mode SPEED H operating hours Setup menu...

Page 36: ... speed to the road conditions and your riding ability Warning Danger of accidents The vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of accidents The brake system fails in the event of overheating If the foot brake lever is not released the brake linings drag continuously Take your foot off the foot brake lever when you are not braking Warning Danger of acc...

Page 37: ...s Guideline Maximum permissible overall weight 280 kg 617 lb Maximum permissible front axle load 110 kg 243 lb Maximum permissible rear axle load 170 kg 375 lb Check the spoke tension p 100 Info The spoke tension must be checked after half an hour of operation Run the engine in p 35 8 2 Running in the engine During the running in phase do not exceed the specified engine speed and engine performanc...

Page 38: ...does not or only weakly turns over the electric starter when temperatures are below 15 C 60 F then the battery is not faulty but needs to be warmed up internally to increase its starting power current output The starting power increases as the battery warms up ...

Page 39: ...heck the tire condition p 98 Check the tire air pressure p 99 Check the spoke tension p 100 Info The spoke tension must be checked regularly as incor rect spoke tension will strongly impair riding safety Clean the dust boots of the fork legs p 54 Bleed the fork legs p 53 Check the air filter Check the settings of all controls and ensure that they can be operated smoothly Check all screws nuts and ...

Page 40: ...ngage 1st gear release the clutch lever slowly and simultaneously open the throttle carefully 9 4 Shifting riding Warning Danger of accidents If you change down at high engine speed the rear wheel blocks and the engine races Do not change into a low gear at high engine speed Info If you hear unusual noises while riding stop immediately switch off the engine and contact an authorized KTM workshop F...

Page 41: ...e linings and the brake discs On sandy wet or slippery surfaces use the rear brake Braking should always be completed before you go into a bend Change down to a lower gear appropriate to your road speed On long downhill stretches use the braking effect of the engine Change down one or two gears but do not overstress the engine In this way you have to apply the brakes far less frequently and the br...

Page 42: ...nition remains switched on at the ignition lock power continues to flow to most power consumers This discharges the battery You should therefore always switch off the engine with the ignition lock the emergency OFF switch is intended for emergencies only Park the motorcycle on firm ground 9 7 Transporting Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a fir...

Page 43: ...r 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 the fuel filter to quickly become clogged In some countries and regions the available fuel quality and cleanliness may not be sufficient This will result in problems with the fuel system Refuel only with clean fuel that meets the specified standards Your a...

Page 44: ...ront brake linings p 87 Check the rear brake linings p 92 Check the brake discs p 84 Check the brake lines for damage and leakage Change the foot brake cylinder seals Check the rear brake fluid level p 90 Check the free travel of the foot brake lever p 89 Check the frame p 79 Check the swingarm p 79 Check the swingarm bearing for play Check the heim joint for play Check the tire condition p 98 Che...

Page 45: ...rvice entry in the KTM Dealer net and in the Service and Manufacturer Warranty Booklet One time interval Periodic interval 10 3 Recommended work Annually Every 160 operating hours Once after 40 operating hours Once after 20 operating hours Change the front brake fluid Change the rear brake fluid Change the hydraulic clutch fluid p 82 Grease the steering head bearing p 61 Service the fork Service t...

Page 46: ...peed and low speed High speed and low speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed The high speed setting for example has an effect on the landing after a jump the rear wheel suspension com presses quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses slowly These two ranges...

Page 47: ...1 4 Adjusting the high speed compression damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized KTM workshop will be glad to help Info The high speed setting can be seen during the fast compressi...

Page 48: ...e around if the shock absorber is detached incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized KTM workshop will be glad to help F01186 10 Turn adjusting screw 1 clockwise up to the last perceptible click Turn counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfor...

Page 49: ... the static sag of the shock absorber 400989 10 Measure distance A of rear wheel unloaded p 46 Hold the motorcycle upright with the aid of an assistant Measure the distance between the rear axle and the fixed point again Note down the value as dimension B Info The static sag is the difference between measurements A and B Check the static sag Static sag 25 mm 0 98 in If the static sag is less or mo...

Page 50: ...A and C Check the riding sag Riding sag 95 mm 3 74 in If the riding sag differs from the specified measurement Adjust the riding sag p 49 11 9 Adjusting the spring preload of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description p...

Page 51: ...ng M5 5 Nm 3 7 lbf ft Finishing work Install the shock absorber p 63 Lock the seat p 64 Remove the motorcycle from the lift stand p 53 11 10 Adjusting the riding sag Preparatory work Raise the motorcycle with a lift stand p 53 Fold the seat up p 64 Remove the shock absorber p 63 After removing the shock absorber clean it thoroughly B00292 10 Main work Choose and mount a suitable spring Guideline S...

Page 52: ...aded hard end stop on com pression harder springs must be fit to avoid damage to the fork and frame 11 12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior F01196 10 Turn white adjusting screw 1 clockwise as far as it will go Info Adjusting screw 1 is located at the upper end of the left fork leg The compression damping is ...

Page 53: ...left fork leg COMP white adjusting screw Turn counterclockwise by the number of clicks corresponding to the fork type Guideline Rebound damping Comfort 23 clicks Standard 20 clicks Sport 15 clicks Info Turn clockwise to increase damping turn counterclock wise to reduce damping 11 14 Handlebar position H02563 10 On the upper triple clamp there are two holes at a distance of A to each other Hole dis...

Page 54: ...one side Info Cover the components to protect them against damage Do not bend the cables and lines Remove screws 2 Take off the handlebar supports Move the handlebar supports into the desired position Mount and tighten screws 2 Guideline Screw handle bar support M10 40 Nm 29 5 lbf ft Loctite 243 Info Position the left and right handlebar supports evenly Position the handlebar Info Make sure cables...

Page 55: ...age The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 401943 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle fold side stand 1 down to the ground with your foot and rest the motorcycle on it Info While riding the side stand must be folded up and secured with the rubber band 12 3 Bleeding the fork legs Preparatory wo...

Page 56: ...d can start to leak 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 nec essary Clean and oil the dust boots and inner fork tubes of both fork legs Universal oil spray p 147 Press the dust boots back into their installation position Remove excess oil Finishing wor...

Page 57: ... tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line wiring harness and clamp Mount and tighten screws 3 12 7 Removing the fork legs Preparatory work Remove the headlight mask with the headlight p 106 Raise the motorcycle with a lift stand p 53 Remove the front wheel p 95 F01199 10 Main work Remove screws 1 and take off the clamp Remove the cable tie s a...

Page 58: ...dge of the upper triple clamp F01201 11 Tighten screws 2 Guideline Screw top triple clamp M8 22 Nm 16 2 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 18 Nm 13 3 lbf ft F01200 10 Position the brake caliper Mount and tighten screws 4 with the spacers Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Connect plug in connector 5 and mount the cable tie s Position th...

Page 59: ...cable holder 1 in front of the right and right radiator and detach the wiring harness F01204 10 Pull the fuel tank breather hose out of the steering head screw Remove screw 2 Remove screw 3 Take off the upper triple clamp with the handlebar and set it aside Info Cover the components to protect them against damage Do not kink the cables and lines F01205 10 Remove O ring 4 and protective ring 5 Take...

Page 60: ...he upper triple clamp with the handlebar Mount screw 4 but do not tighten yet Position the clutch line and wiring harness F01188 10 Position the fork legs Bleeder screws 5 are positioned toward the front Info The rebound damping is located in right fork leg REB red adjusting screw The compression damping is located in left fork leg COM white adjusting screw Grooves are milled into the side of the ...

Page 61: ... M8 22 Nm 16 2 lbf ft F01203 11 Secure cable holder 9 in front of the right and left radiator Insert the fuel tank breather hose into the steering head screw F01200 11 Position the brake caliper Mount and tighten screws bk with the spacers Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Connect plug in connector bl and mount the cable tie s Position the brake line wiring harne...

Page 62: ...ng head bearing the bearing and the bearing seats in the frame can become damaged over time Preparatory work Raise the motorcycle with a lift stand p 53 H01167 01 Main work Move the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel No play should be noticeable in the steering head bearing If there is noticeable play present Adjust the play of the ste...

Page 63: ...y on the upper triple clamp to avoid strains Tighten screws 2 Guideline Screw top triple clamp M8 22 Nm 16 2 lbf ft Mount and tighten screw 3 Guideline Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 243 Insert hose 1 into the steering head screw Finishing work Check the steering head bearing play p 60 Remove the motorcycle from the lift stand p 53 12 13 Greasing the steering head bearing H02...

Page 64: ...lling front fender E00985 10 Main work Position front fender Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the headlight mask with the headlight p 107 Check the headlight setting p 109 ...

Page 65: ...in work Push splash protector 1 to the side and position the shock absorber Mount and tighten screw 2 Guideline Screw top shock absorber M12 80 Nm 59 lbf ft Loctite 2701 Mount and tighten screw 3 Guideline Screw bottom shock absorber M12 80 Nm 59 lbf ft Loctite 2701 Info The heim joint for the shock absorber at the swingarm is Teflon coated It must not be greased with grease nor with any other lub...

Page 66: ...ever 1 Lift the seat and fold it up 12 19 Locking the seat E00977 10 Fold down the seat and push it down The seat engages with an audible click Check that the seat is correctly locked 12 20 Taking off the spoiler Preparatory work Fold the seat up p 64 F01211 10 Main work Remove screws 1 ...

Page 67: ...he spoiler and hook it in at area A F01212 11 Mount and tighten screw 1 Guideline Screw for spoiler top EJOT PT K60x20AL 3 Nm 2 2 lbf ft Mount and tighten screw 2 Guideline Screw for spoiler attachment M6 5 Nm 3 7 lbf ft F01211 11 Mount and tighten screws 3 Guideline Screw front spoiler EJOT PT K60x30 Z 3 Nm 2 2 lbf ft Repeat the operation on the opposite side Finishing work Lock the seat p 64 ...

Page 68: ...ter housing Note Engine failure If the pre filter is mounted incorrectly or not mounted at all the air fuel mixture will change This has a negative effect on the service life of the engine Make sure the pre filter is seated correctly Attach air filter housing 2 to the inlet flange together with the mounted pre filter Info If the air filter housing is not mounted correctly dust and dirt may enter t...

Page 69: ...2 together and open in counter clockwise direction Remove the air filter3 with the air filter support4 Take off air filter 3 from air filter support 4 12 25 Installing the air filter B01757 10 Main work Mount the clean air filter onto the air filter support Apply grease to the air filter around area A Long life grease p 146 M00507 10 Insert both parts together and close air filter housing 1 by tur...

Page 70: ...leaning liquid and allow it to dry properly Air filter cleaner p 146 Info Only press the air filter to dry it never wring it out Oil the dry air filter with a high quality filter oil Oil for foam air filter p 146 Clean the air filter housing Check the intake flange for damage and ensure it is firmly seated Finishing work Install the air filter p 67 Install the air filter housing p 66 Lock the seat...

Page 71: ...crew 2 Guideline Screw main silencer M8x20 25 Nm 18 4 lbf ft Repeat these steps on the opposite side 12 29 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehicle Info Over a period the fibers of the glass fiber yarn vanish into the ...

Page 72: ...fuel tank expands when warm and can escape if overfilled Do not refuel the vehicle in the vicinity of open flames or lit cigarettes 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...

Page 73: ...er into the fuel line Dirt in the fuel line clogs the injection valve Disconnect the plug in connection of the fuel line Info Remaining fuel may flow out of the fuel hose Mount wash cap set 1 Wash cap set 81212016100 F01165 10 Remove the hose from the fuel tank breather Remove screws 2 on both sides Remove screw 3 F01166 10 Unplug connector 4 Pull off engine breather hose 5 ...

Page 74: ...o 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 of skin contact rinse the affected area with plenty of...

Page 75: ... Loctite 243 Mount and tighten screw 6 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Attach the fuel tank breather hose F01168 10 Thoroughly clean the plug in connection of the fuel line using compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Remove the wash cap set Lubricate the O ring and connect plug in conne...

Page 76: ...p the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info The service life of the chain depends largely on its maintenance Preparatory work Raise the m...

Page 77: ...Info The lower chain section 1 must be taut Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 36 40 mm 1 42 1 57 in If the chain tension does not meet specifications Adjust the chain tension p 75 Finishing work Remove the motorcycle from the lift stand p 53 12 35 Adjusting the chain tension Warning Danger of accidents Incorrect chain ten...

Page 78: ...g screws 3 Tighten nut 1 Guideline Nut rear wheel spin dle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters enables different secondary ratios with the same chain length Chain adjusters 4 can be turned by 180 Finishing work Remove the motorcycle from the lift stand p 53 12 36 Checking the chain rear sprocket engine sprocket and chain guide Preparatory work Raise the mo...

Page 79: ...10 71 in If the distance B is greater than the specified measure ment Change the drivetrain kit Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out faster on old worn sprock ets F01193 10 Check the chain sliding guard for wear If the bottom edge of the chain bolt is in line with or below the chain sliding guard Change the chain sliding g...

Page 80: ...in sliding piece Guideline Screw chain slid ing piece M8 15 Nm 11 1 lbf ft 400985 01 Check the chain guide for wear Info Wear can be seen on the front of the chain guide If the light part of the chain guide is worn Change the chain guide F01192 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the fitting on the chain guide Guideline Remaining screws chassis M6 10 ...

Page 81: ...cking and deformation If the swingarm shows signs of damage cracking or defor mation Change the swingarm Info Always change a damaged swingarm Repair of the swingarm is not authorized by KTM 12 39 Checking the throttle cable routing Preparatory work Fold the seat up p 64 Remove the fuel tank p 70 F01163 01 Main work Check the throttle cable routing Both throttle cables must be routed to the thrott...

Page 82: ...ted Guideline Screw fixed grip M4 5 Nm 3 7 lbf ft Loctite 243 Diamond A must be located at the top 12 41 Adjusting the basic position of the clutch lever E01002 10 Adjust the basic position of the clutch lever to your hand size by turning adjusting screw 1 Info When the adjusting screw is turned clockwise the clutch lever moves away from the handlebar When the adjusting screw is turned countercloc...

Page 83: ...if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info The fluid level rises with increasing wear of the clutch facing discs Never use ...

Page 84: ...spills on to your clothing change the clothing Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Avoid co...

Page 85: ...sition the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immediately with water 12 45 Removing the engine guard E00964 10 Remove screws 1 and 2 Lower the engine guard at the rear and remove it toward the front 12 46 Installing the engine guard E00964 10 Position the engine guard on the frame at the front and mount screws 1 but do not tighten y...

Page 86: ...justing the free travel of the handbrake lever E01007 10 Check the free travel of the hand brake lever p 84 Adjust the free travel of the handbrake lever with adjustment screw 1 Info Turn the adjusting screw clockwise to reduce free travel The pressure point moves away from the handlebar Turn the adjusting screw counterclockwise to increase free travel The pressure point moves towards the han dleb...

Page 87: ... front brake Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value 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 Dang...

Page 88: ...t 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 Warning Environmental hazard Hazardous substances cause environmental damage Dispose of oils g...

Page 89: ...TM workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear 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 cont...

Page 90: ...egulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container E01008 11 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2...

Page 91: ...fluid level below reservoir rim 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 144 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immediately with water 13 8 Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressur...

Page 92: ...f the foot brake lever Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Hold screw 3 and tighten nut 2 Guideline Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Hold push rod 5 and tighten nut 4 Guideline Remaining nuts chassis M6 10 Nm 7 4 lbf ft Reconnect spring 1 13 10 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the bra...

Page 93: ... 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 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 ...

Page 94: ...g effect Ensure that worn out brake linings are replaced immediately Your authorized KTM workshop will be glad to help E01016 10 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings p 92 Check the brake linings for damage and cracking If damage or cracking is visible Change the rear brake lini...

Page 95: ...en approved alter the braking efficiency Not all brake linings are tested and approved for KTM motorcycles The structure and friction coefficient of the brake linings and thus their brake power may vary greatly from that of original brake linings If brake linings are used that differ from the original equipment compliance with the original homologa tion is not guaranteed In this case the vehicle n...

Page 96: ...To make it easier to mount the pin push the retainer spring down Make sure the retaining spring is seated correctly Mount cotter pins 3 Operate the foot brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point E01015 10 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 144 Position the cover with the washer and membrane 2 Mount and tight...

Page 97: ...iscs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork Info Do not pull the hand brake lever when the front wheel is removed H00934 10 Remove spacers 3 14 2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the brak...

Page 98: ...sert the wheel spindle The brake linings are correctly positioned Mount and tighten screw 2 Guideline Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Operate the hand brake lever several times until the brake lin ings are seated correctly against the brake disc Remove the motorcycle from the lift stand p 53 Operate the front brake and compress the fork a few times firmly The fork legs straight...

Page 99: ...g the rear wheel withdraw the wheel spindle Take the rear wheel out of the swingarm Info Do not operate the foot brake lever when the rear wheel is removed H00936 10 Remove spacers 4 14 4 Installing the rear 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 n...

Page 100: ...ters 3 can be turned by 180 Operate the foot brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand p 53 14 5 Checking the tire condition Info Only mount tires approved and or recommended by KTM Other tires could have a negative effect on handling characteristics The type condition an...

Page 101: ...e week of manufacture and the last two digits the year of manu facture KTM recommends that the tires be changed after 5 years at the latest regardless of the actual state of wear If the tires are more than 5 years old Change the tires 14 6 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 co...

Page 102: ... glad to help Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle 400694 01 Briefly strike each spoke with the tip of a screwdriver Info The tone frequency depends on the length of the spoke and the spoke diameter If you hear different tone ...

Page 103: ...in work Remove screw 1 Remove fastening plate 2 E00981 10 Remove the battery from the battery compartment Warning Risk of injury Batteries contain harmful substances Keep batteries out of the reach of children Keep sparks and open flames away from the batter ies Only charge batteries in well ventilated rooms Maintain a minimum clearance from inflammable materials when charging batteries Minimum cl...

Page 104: ... under the screw 1 and the cable lug 2 with the claws toward the battery terminal E00980 11 Position the battery in the battery compartment Attach fastening plate 4 Mount and tighten screw 5 15 3 Recharging the battery Warning Risk of injury Batteries contain harmful substances Keep batteries out of the reach of children Keep sparks and open flames away from the batteries Only charge batteries in ...

Page 105: ...y will be destroyed If the battery is depleted by repeated starting 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 sul fated destroying the battery The battery is maintenance free Preparatory work Turn the key in the ignition lock to the position while the engine is idling Remove the battery p 101 S0086...

Page 106: ...ired ampere value Do not bypass or repair fuses Info The main fuse protects all power consumers of the vehicle It is located behind the battery Preparatory work Turn the key in the ignition lock to the position while the engine is idling Raise the motorcycle with a lift stand p 53 Fold the seat up p 64 Remove the shock absorber p 63 E01025 10 Main work Take off protection caps 1 E01026 10 Remove f...

Page 107: ... 64 E01027 10 Main work Pull EFI control unit 1 off the holder and hang to the side Open fuse box cover 2 E01028 10 Remove the faulty fuse Guideline Fuse 1 10 A EFI control unit lambda sensor injection valve combination instrument diagnostics connector Fuse 2 10 A high beam low beam parking light tail light license plate lamp Fuse 3 10 A horn turn signal brake light radiator fan Fuse 4 10 A fuel p...

Page 108: ... properly Close the fuse box cover F01176 10 Mount EFI control unit 1 on the holder Finishing work Lock the seat p 64 15 6 Removing the headlight mask with the headlight Turn the key in the ignition lock to the position while the engine is idling E00973 11 Detach the brake line and wiring harness 1 Release rubber bands 2 Slide the headlight mask up and swing it forward ...

Page 109: ...t mask with the headlight E00968 10 Main work Join plug in connector 1 of the turn signal relay plug in con nectors 2 of the turn signals plug in connector 3 of the headlight and plug in connector 4 of the ignition lock E00973 10 Attach the brake line and wiring harness 5 Position the headlight mask and secure it with rubber bands 6 The holding lugs on the fender engage in the headlight mask Finis...

Page 110: ... parking light out of the reflector E01030 10 Pull out headlight bulb 3 Insert the new headlight bulb Headlight HS1 socket PX43t p 140 Insert the protection cap with the bulb socket into the reflector and turn it clockwise all the way Info Ensure that O ring 4 is seated properly Insert the bulb socket of the parking light into the reflector Finishing work Install the headlight mask with the headli...

Page 111: ...terclockwise until it engages in the thread Tighten the screw slightly Finishing work Check that the turn signal system is functioning properly 15 10 Checking the headlight setting 0 0 A A 0 0 B B 400726 10 Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight Make another mark at a distance B under the f...

Page 112: ...ation instrument Preparatory work Remove the headlight mask with the headlight p 106 E01031 10 Main work Remove screws 1 Pull the combination instrument upward out of the holder E01032 10 Using a coin turn protection cap 2 all the way counterclock wise and remove it Remove combination instrument 3 Insert the new battery with the label facing outward Combination instrument battery CR 2430 p 140 Che...

Page 113: ...headlight mask with the headlight p 107 Check the headlight setting p 109 Adjust kilometers or miles p 22 Adjust the combination instrument p 23 Adjust the clock p 24 15 13 Diagnostics connector H00933 12 Diagnostics connector 1 is located under the seat ...

Page 114: ...er 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 other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of po...

Page 115: ...ine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediatel...

Page 116: ... Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eye...

Page 117: ...ediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing E01035 10 Main work Make sure that screw 1 is tightened Stand the motorcycle upright Pour coolant in up to measurement A above the radiator fins Guideline 10 mm 0 39 in Coolant 0 7 l ...

Page 118: ...ay result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction system when starting or running the engine in an enclosed space Start the engine and let it run idle Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle c...

Page 119: ... there is play in the throttle cable at the throttle grip Guideline Throttle cable play 3 5 mm 0 12 0 2 in Tighten nut 2 Slide on sleeve 1 Check the throttle grip for smooth operation Finishing work Check the play in the throttle cable p 116 17 3 Adjusting the characteristic map of the throttle response Info On the throttle grip the characteristic map of the throttle response is changed by changin...

Page 120: ...upon delivery S01320 10 Clean the outside of the handlebar and the inside of the grip tube Mount the grip tube on the handlebar Attach the throttle cables to the guide plate and route cor rectly Position half shells 3 mount and tighten screws 2 Guideline Screw for throttle grip M6 5 Nm 3 7 lbf ft Slide on sleeve 1 and check the throttle grip for ease of movement Finishing work Check the play in th...

Page 121: ...ffect on the service life of the engine Dust and dirt will enter the engine without an air filter Never start to use the vehicle without an air filter Remove the air filter housing p 66 Adjust the idle speed by turning idle speed adjusting screw 1 Info 1 4 turn of the idle speed adjusting screw corresponds to approx 50 rpm Adjust the idle speed in small steps Turning counterclockwise lowers the id...

Page 122: ...ehicle to idle The malfunction indicator lamp stops flashing once teach ing is completed Info If the engine becomes too hot perform a cool down ride at medium revs Then do not switch off the engine after this but leave it running at idle speed until teaching is completed 17 6 Checking the basic position of the shift lever Info When driving the shift lever must not touch the driver s boot when in t...

Page 123: ...th A of the shift lever and shift shaft Mount the shift lever on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle components during the shift procedure Mount and tighten screw 1 with washers Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 ...

Page 124: ...f 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 Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system F01215 10 Main work Clean plug in...

Page 125: ...level The engine oil is at a level between the lower edge A and the middle B of the level viewer If the engine oil is not up to the lower edge A of the level viewer Add engine oil p 126 18 3 Changing the engine oil and oil filter cleaning the oil screen Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden Wear suitable protective clothing and safety gloves In t...

Page 126: ... Position oil screen 4 with the O rings on a pin wrench Position the pin wrench through the drill hole of the screw plug in the opposite section of the engine case Push the oil screen all the way into the engine case F01216 10 Mount and tighten screw plug 3 with the O ring Guideline Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ft Mount and tighten oil drain plug 1 with the magnet and a new seal ri...

Page 127: ...orcycle upright 401955 12 Remove filler plug 8 from the clutch cover together with the O ring and fill up with engine oil Engine oil 1 0 l 1 1 qt Engine oil SAE 10W 50 p 144 Info Too little engine oil or poor quality engine oil will result in premature wear of the engine Mount and tighten the filler plug together with the O ring Danger Danger of poisoning Exhaust gases are toxic and inhal ing them...

Page 128: ...ne performance it is not advisable to mix different engine oils We recommended changing the engine oil when neces sary Mount and tighten the filler plug together with the O ring Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use an effective exhaust extraction sys...

Page 129: ...long period Avoid direct sunshine on the motorcycle during cleaning 401061 01 Close off the exhaust system to keep water from entering First 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 146 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply ...

Page 130: ...sion If the vehicle was operated in road salt clean it with cold water after riding Warm water would enhance the corrosive effects of salt 401060 01 Clean the motorcycle p 127 Clean the brake system Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts are cooled down and while they are insta...

Page 131: ... workshop waiting times at the start of the new season 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 146 Refuel p 41 Clean the motorcycle p 127 Change the engine oil and oil filter clean the oil screen p 123 Check the antifreeze and coolant level p 112 Check the tire air pressure p 99 Remove the battery p 101 Recharge the b...

Page 132: ...E 130 20 2 Preparing for use after storage 401059 01 Remove the motorcycle from the lift stand p 53 Install the battery p 102 Perform checks and maintenance measures when preparing for use p 37 Take a test ride ...

Page 133: ... Spark plug oily or wet Clean and dry the spark plug or change it if necessary Electrode distance plug gap of spark plug too wide Adjust the plug gap Guideline Spark plug electrode gap 1 0 mm 0 039 in Faulty ignition Ignition coil check the secondary winding Check the spark plug connector Check the stator winding of the alter nator Short circuit cable in wiring harness frayed kill switch or emerge...

Page 134: ...ngine when standing Radiator fins very dirty Clean the radiator fins Foam formation in cooling sys tem Drain the coolant p 114 Refill the coolant p 115 Bent radiator hose Change the radiator hose Defect in radiator fan system Check fuse 3 Check the radiator fan Malfunction indicator lamp lights up or flashes Defect in fuel injection system Stop the motorcycle and identify the faulty part using the...

Page 135: ...instrument is discharged Change the combination instrument p 110 The high beam low beam parking light tail light and license plate lamp are not working Fuse 2 blown Change the fuses of individual power consumers p 105 The horn turn signal brake light and radiator fan are not working Fuse 3 blown Change the fuses of individual power consumers p 105 ...

Page 136: ...anifold absolute pressure sensor cylinder 1 input signal too low Manifold absolute pressure sensor cylinder 1 input signal too high Blink code for malfunction indicator lamp 12 Malfunction indicator lamp flashes 1x long 2x short Error level condition Engine coolant temperature sensor input signal too low Engine coolant temperature sensor input signal too high Blink code for malfunction indicator l...

Page 137: ...unction indicator lamp flashes 3x long 3x short Error level condition Injector cylinder 1 circuit fault Blink code for malfunction indicator lamp 37 Malfunction indicator lamp flashes 3x long 7x short Error level condition Ignition coil 1 cylinder 1 circuit fault Blink code for malfunction indicator lamp 41 Malfunction indicator lamp flashes 4x long 1x short Error level condition Fuel pump relay s...

Page 138: ...r bearings Conrod bearing Slide bearing Piston pin bearing Bearing bush Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with two Eaton pumps Primary transmission 24 73 Clutch Multidisc clutch in oil bath hydraulically activated Transmission ratio First gear 13 32 Second gear 16 30 Third gear 16 24 Fourth gear 23 28 F...

Page 139: ... lbf ft Loctite 243 Screw bearing bolt oil pump idler gear M5 6 Nm 4 4 lbf ft Loctite 243 Screw clutch spring M5 6 Nm 4 4 lbf ft Screw crankshaft position sensor M5 6 Nm 4 4 lbf ft Loctite 243 Screw gear position sensor M5 5 Nm 3 7 lbf ft Loctite 243 Screw locking lever M5 6 Nm 4 4 lbf ft Loctite 243 Screw oil pump cover M5 6 Nm 4 4 lbf ft Loctite 243 Screw stator M5 6 Nm 4 4 lbf ft Loctite 243 Nu...

Page 140: ...g cam lever axis M10x1 10 Nm 7 4 lbf ft Screw unlocking of timing chain tensioner M10x1 8 Nm 5 9 lbf ft Spark plug M10x1 10 12 Nm 7 4 8 9 lbf ft Engine coolant temperature sensor M10x1 25 12 Nm 8 9 lbf ft Nut cylinder head M10x1 25 Tightening sequence Tighten diagonally 1st tightening stage 10 Nm 7 4 lbf ft 2nd tightening stage 30 Nm 22 1 lbf ft 3rd tightening stage 50 Nm 36 9 lbf ft Thread oiled ...

Page 141: ...k offset 20 mm 0 79 in Shock absorber WP Performance Systems Xplor PDS Brake system front Disc brake with radially mounted four piston brake caliper rear Disc brake with radially mounted dual piston brake caliper Brake discs diameter front 260 mm 10 24 in rear 210 mm 8 27 in Brake discs wear limit front 3 7 mm 0 146 in rear 3 5 mm 0 138 in Tire air pressure offroad front 0 9 bar 13 psi rear 0 7 ba...

Page 142: ...ocket W2 1x9 5d 12 V 5 W Indicator lamps W2 3 W socket W2 1x4 6 d 12 V 2 3 W Turn signal R10W socket BA15s 12 V 10 W Brake tail light LED License plate lamp W5W socket W2 1x9 5d 12 V 5 W 23 6 Tires Front tire Rear tire 2 75 21 M C 45M TT MAXXIS TRIALMAXX 4 00 R 18 M C 64M TL MAXXIS TRIALMAXX The tires specified represent one of the possible series production tires Additional information is availab...

Page 143: ...ound damping Comfort 22 clicks Standard 15 clicks Sport 12 clicks Spring preload 10 mm 0 39 in Spring rate Weight of rider 65 75 kg 143 165 lb 66 N mm 377 lb in Weight of rider 75 85 kg 165 187 lb 68 N mm 388 lb in Weight of rider 85 95 kg 187 209 lb 69 N mm 394 lb in Spring length 200 mm 7 87 in Gas pressure 10 bar 145 psi Static sag 25 mm 0 98 in Riding sag 95 mm 3 74 in Fitted length 367 mm 14 ...

Page 144: ...5 Nm 3 7 lbf ft Fuel connection on fuel pump M8 10 Nm 7 4 lbf ft Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Nut rear sprocket screw M8 35 Nm 25 8 lbf ft Loctite 2701 Nut rim lock M8 10 Nm 7 4 lbf ft Remaining nuts chassis M8 25 Nm 18 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft Screw of rear brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw bottom triple clamp M8 18 Nm 13 3 lbf ft...

Page 145: ... ft Screw foot brake lever M10 30 Nm 22 1 lbf ft Loctite 243 Screw footrest bracket M10 45 Nm 33 2 lbf ft Loctite 243 Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Screw upper subframe M10 45 Nm 33 2 lbf ft Loctite 243 Nut fuel pump fixation M12 15 Nm 11 1 lbf ft Screw bottom shock absorber M12 80 Nm 59 lbf ft Loctite 2701 Screw top shock absorber M12 80 Nm 59 lbf ft Loctite 2701 Nut s...

Page 146: ...ties 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 specification...

Page 147: ...E 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe ...

Page 148: ...r High viscosity grease Recommended supplier SKF LGHB 2 Long life grease Recommended supplier Motorex Bike Grease 2000 Motorcycle cleaner Recommended supplier Motorex Moto Clean Off road chain spray Recommended supplier Motorex Chainlube Offroad Oil for foam air filter Recommended supplier Motorex Racing Bio Liquid Power Preserving materials for paints metal and rubber Recommended supplier Motorex...

Page 149: ...Y SUBSTANCES 25 147 Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommended supplier Motorex Quick Cleaner Universal oil spray Recommended supplier Motorex Joker 440 Synthetic ...

Page 150: ...rvice 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 MA standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to...

Page 151: ...INDEX OF SPECIAL TERMS 27 149 OBD On board diagnosis Vehicle system which monitors the specified parame ters of the vehicle electronics ...

Page 152: ...28 LIST OF ABBREVIATIONS 150 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 153: ...ts up flashes yellow The OBD has detected an error in the vehicle electronics Come safely to a halt and contact an authorized KTM workshop The fuel level warning lamp lights up yellow The fuel level has reached the reserve mark 29 2 Green and blue symbols Green and blue symbols reflect information The high beam indicator lamp lights up blue The high beam is switched on Turn signal indicator lamp f...

Page 154: ...ain checking 76 cleaning 74 Chain guide checking 76 Chain tension adjusting 75 checking 75 Characteristic map of the throttle response adjusting 117 Chassis number 13 Clutch fluid level checking 80 fluid level correcting 81 fluid changing 82 Clutch lever 15 basic position adjusting 80 Cold start button 18 Combination instrument adjusting 23 adjusting kilometers or miles 22 adjusting the clock 24 b...

Page 155: ...108 Headlight mask with headlight installing 107 removing 106 Headlight setting checking 109 High speed compression damping shock absorber adjusting 45 Horn button 16 I Idle speed adjusting 118 Idle speed adjusting screw 19 Ignition lock 20 Implied warranty 9 Indicator lamps overview 17 Intended use 6 K Key number 13 Kill switch 15 L Light switch 16 Lower triple clamp installing 58 removing 57 Low...

Page 156: ...ension checking 100 Starting 37 Starting power of lithium ion batteries at low tempera tures 35 Steering locking 21 unlocking 21 Steering head bearing greasing 61 Steering head bearing play adjusting 61 checking 60 Storage 129 130 Swingarm checking 79 T Technical data capacities 139 chassis 139 chassis tightening torques 141 electrical system 140 engine 136 engine tightening torques 137 fork 140 s...

Page 157: ... 3213652en 3213652en 08 2017 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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