KTM RC 390 Owner'S Manual Download | Manualshive

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MEANS OF REPRESENTATION

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Symbols used

The meaning of specific symbols is described below.

Indicates an expected reaction (e.g. of a work step or a function).

Indicates an unexpected reaction (e.g. of a work step or a function).

All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your
own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be optimally
cared for by specially trained experts using the specialist tools required.

Indicates a page reference (more information is provided on the specified page).

Indicates information with more details or tips.

Indicates the result of a testing step.

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Summary of Contents for RC 390

Page 1: ...OWNER S MANUAL 2016 RC 250 Art no 3213408en...

Page 2: ......

Page 3: ...differences due to develop ments in design cannot be ruled out completely All specifications are non binding KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical spec...

Page 4: ...1 12 100 6061 According to the international quality management standard ISO 9001 KTM uses quality assurance processes that lead to the maximum possible quality of the products Issued by T V Managemen...

Page 5: ...right example 18 5 SERIAL NUMBERS 20 5 1 Chassis number 20 5 2 Type label 20 5 3 Engine number 21 5 4 Key number 21 6 CONTROLS 22 6 1 Clutch lever 22 6 2 Hand brake lever 22 6 3 Throttle grip 23 6 4...

Page 6: ...eparing for use 60 9 2 Starting 61 9 3 Starting off 63 9 4 Shifting riding 63 9 5 Applying the brakes 66 9 6 Stopping parking 68 9 7 Transport 69 9 8 Refueling 70 10 SERVICE SCHEDULE 72 10 1 Additiona...

Page 7: ...ber dampers 118 14 6 Checking the tire condition 120 14 7 Checking the tire air pressure 121 15 ELECTRICAL SYSTEM 123 15 1 Removing the battery 123 15 2 Installing the battery 124 15 3 Recharging the...

Page 8: ...K CODE 165 23 TECHNICAL DATA 171 23 1 Engine 171 23 2 Engine tightening torques 172 23 3 Capacities 175 23 3 1 Engine oil 175 23 3 2 Coolant 175 23 3 3 Fuel 175 23 4 Chassis 175 23 5 Electrical system...

Page 9: ...th this symbol requires specialist knowledge and technical understanding In the interest of your own safety have these jobs performed by an authorized KTM workshop There your motorcycle will be optima...

Page 10: ...document are explained below Specific name Identifies a proprietary name Name Identifies a protected name Brand Identifies a brand available on the open market Underlined terms Refer to technical det...

Page 11: ...version only 2 2 Safety advice A number of safety instructions need to be followed to operate the vehicle safely Therefore read this manual carefully The safety instruc tions are highlighted in the te...

Page 12: ...Warning Indicates a danger that will lead to environmental damage if the appropriate measures are not taken 2 4 Tampering warning Tampering with the noise control system is prohibited Federal law pro...

Page 13: ...may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust...

Page 14: ...s In some instances a thread locker e g Loctite is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them for damage and...

Page 15: ...hen will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it as...

Page 16: ...ironmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Use operating and auxiliary substances such as...

Page 17: ...inspect or replace parts before the next scheduled service It is imperative that you adhere to the stipulated run in times and service intervals If you observe these exactly you will ensure a much lo...

Page 18: ...4 VIEW OF VEHICLE 16 4 1 View of vehicle front left example S00777 10...

Page 19: ...VIEW OF VEHICLE 17 1 Horn button p 23 1 Light switch p 24 1 High beam flasher button p 24 1 Turn signal switch p 25 2 Clutch lever p 22 3 Filler cap 4 Seat lock p 29 5 Side stand p 33 6 Shift lever p...

Page 20: ...4 VIEW OF VEHICLE 18 4 2 View of vehicle rear right example S00778 10...

Page 21: ...1 Grab handles p 30 2 Tool set p 30 3 Ignition steering lock p 26 4 Emergency OFF switch p 25 4 Electric starter button p 26 5 Throttle grip p 23 6 Hand brake lever p 22 7 Passenger footrests p 31 8 F...

Page 22: ...ERS 20 5 1 Chassis number 402175 10 The chassis number is stamped on the right side of the frame under the seat 5 2 Type label 0 0 1 1 402174 10 The type label is on the right of the frame behind the...

Page 23: ...0 The engine number is stamped on the left side of the engine under the engine sprocket 5 4 Key number 402245 10 The key number can be found on the KEYCODECARD Info You need the key number to order a...

Page 24: ...ever L02111 10 The clutch lever is fitted on the left side of the handlebar 6 2 Hand brake lever L02112 10 The hand brake lever is fitted on the right side of the handlebar The front brake is engaged...

Page 25: ...rottle grip is fitted on the right side of the handlebar 6 4 Horn button L02113 10 The horn button is fitted on the left side of the handlebar Possible states Horn button in neutral position Horn butt...

Page 26: ...re switched on High beam on The light switch is turned upwards In this position the low beam the high beam and the tail light are switched on 6 6 High beam flasher button L02113 12 The high beam flash...

Page 27: ...the right The turn signal switch returns automatically to the central position after use To switch off the turn signal press the turn signal switch towards the switch case 6 8 Emergency OFF switch L0...

Page 28: ...teering lock L02115 01 The ignition steering lock is in front of the upper triple clamp Possible states Ignition OFF In this position the ignition circuit is interrupted a running engine stops and a n...

Page 29: ...400732 01 Park the vehicle Turn the handlebar all the way to the left Insert the key into the ignition handlebar lock press in and turn to the left Remove the key Steering is no longer possible 6 12...

Page 30: ...occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Chan...

Page 31: ...closing the filler cap ensure that it is locked properly Change cloth ing that has been contaminated with fuel Immediately clean contaminated areas on the skin with soap and water Close the filler ca...

Page 32: ...10 The tool set is in the storage compartment under the seat 6 17 Grab handles K00020 10 The grab handles are used for moving the motorcycle around If you carry a passenger the passenger can hold ont...

Page 33: ...r footrests can be folded in and out Possible states Passenger footrests folded up For operation without a passenger Passenger footrests folded down For operation with a passenger 6 19 Shift lever 401...

Page 34: ...can be seen in the photograph The neutral or idle position is between the first and second gears 6 20 Foot brake lever 402177 10 Foot brake lever is located in front of the right footrest The foot bra...

Page 35: ...side stand must be folded up during motorcycle use Side stand is coupled with the safety start system see the riding instructions Possible states Side stand folded out The vehicle can be leaned on th...

Page 36: ...7 COMBINATION INSTRUMENT 34 7 1 Overview 401685 10 1 Display p 41 2 Function buttons p 39 3 Info display p 45 4 Indicator lamps p 40...

Page 37: ...is switched on Test The segments of the tachometer and the gear display light up and switch off in sequence The speed display counts from 0 to 199 and back The remaining display segments outside the i...

Page 38: ...INSTRUMENT 36 7 3 Warning notes 401309 01 Low Oil Pressure appears on the info display if the oil pressure is too low 401310 01 Low Fuel Level appears on the info display if the fuel level reaches the...

Page 39: ...oolant temperature rises above the specified value Coolant temperature 125 C 257 F 401312 01 Side Stand Down appears on the info display if the side stand is folded down 401313 01 Low Battery appears...

Page 40: ...rvice Not Reset appears on the info display for 10 seconds when the ignition is switched on and the distance interval between service appointments has been exceeded or the service interval display was...

Page 41: ...display modes are total distance traveled TRIP 1 distance 1 ODO and distance 2 TRIP 2 Pressing and holding the SET button resets the distance 1 TRIP 1 and distance 2 TRIP 2 functions to 0 0 and brief...

Page 42: ...red The set shift speed has been reached The idling speed indicator lamp lights up green The transmission is shifted to idle The high beam indicator lamp lights up blue The high beam is switched on Th...

Page 43: ...minute The gear display shows the engaged gear The coolant temperature appears in segment The time appears in segment The filling level in the fuel tank is displaced in segment The info display shows...

Page 44: ...7 COMBINATION INSTRUMENT 42 7 7 Filling level display in fuel tank 401292 01 The filling level display consists of 9 bars The more bars are lit the more fuel is in the fuel tank...

Page 45: ...the reserve mark the display mode automatically changes to TRIP F and starts to count from 0 0 regardless of the previous display mode Info At the same time as the display mode TRIP F the general war...

Page 46: ...s of 13 bars The more bars that light up the hotter the coolant When all bars light up the following warning note appears on the info display High Coolant Temperature Possible states Engine cold Up to...

Page 47: ...7 COMBINATION INSTRUMENT 45 7 10 Info display 401291 10 Various warning notes appear on info display If the general warning lamp lights up the corresponding warning note is shown on the info display...

Page 48: ...The riding time and average speed are displayed in this menu Info If the ignition was switched off for over 60 minutes the display is reset to 0 Press the SET button briefly Next display mode on the...

Page 49: ...ge fuel consumption 1 average fuel consumption 2 menu 401466 01 Condition Alternative 1 The ignition is on The motorcycle is stationary Alternative 2 The ignition is on The motorcycle is moving Press...

Page 50: ...he SET button briefly and repeatedly until the desired info display appears The average fuel consumption 2 in km L or miles L and the distance to the next service are displayed in this menu Info The a...

Page 51: ...ired info display appears This menu shows the distance to the next service and the range Info The range depends on the average fuel consumption and the fuel quantity in the fuel tank The range is disp...

Page 52: ...e desired info display appears The range and the riding time are displayed in this menu Info The range depends on the average fuel consumption and the fuel quantity in the fuel tank The range is displ...

Page 53: ...ary Alternative 2 The ignition is on The motorcycle is moving Press the MODE button briefly and repeatedly until ODO appears on the display ODO shows the total distance covered Info This value is reta...

Page 54: ...stops TRIP 1 is always running and counts up to 999 9 Press the SET button for 5 10 seconds Display of TRIP 1 is reset Press the MODE but ton Next display mode on the display 7 19 Distance menu 2 TRIP...

Page 55: ...de on the display 7 20 Setting kilometers or miles Info Make the country specific setting Condition The ignition is on The motorcycle is stationary 401303 01 Press the MODE button briefly and repeated...

Page 56: ...e minutes display using the SET button Press the MODE and SET buttons for 5 10 seconds The time is set 7 22 Adjusting the shift speed RPM 1 Condition The ignition is on The motorcycle is stationary 40...

Page 57: ...efly and repeatedly until TRIP 2 appears on the display Press the SET button for 5 10 seconds The display RPM 2 appears Info The engine speed can be set at intervals of 50 RPM 2 is the engine speed ab...

Page 58: ...due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Dange...

Page 59: ...efore making a longer trip Try also to ride as slowly as possible to get a better feel for the vehicle Hold the handlebar firmly with both hands and keep your feet on the footrests when riding Run the...

Page 60: ...arning Danger of accidents Risk of breakage of suitcase system If you have fitted suitcases on your motorcycle read the manufacturer s specifications concerning the maximum payload Warning Danger of a...

Page 61: ...f the vehicle and ensure even weight distribu tion between the front and rear wheels Do not exceed the overall maximum permitted weight and the axle loads Guideline Maximum permissible overall weight...

Page 62: ...p 107 Check the front brake linings p 106 Check the rear brake linings p 109 Check the brake system function Check the coolant level in the compensating tank p 139 Check for chain dirt accumulation p...

Page 63: ...cle is operated with a discharged battery or without a battery electronic components and safety equipment may be damaged Never operate the vehicle with a discharged battery or without a battery Note E...

Page 64: ...up and goes back out after starting off Press the electric starter button Info Do not press the electric starter button until the combination instrument func tion check is finished When starting DO NO...

Page 65: ...eously open the throttle carefully Tip If the engine dies while starting off only pull the clutch lever and press the electric starter button You do not need to shift into neutral 9 4 Shifting riding...

Page 66: ...the minimum age of passengers Warning Danger of accidents Danger of accidents caused by dangerous driving Comply with traffic regulations and ride defensively and foresightedly to detect sources of d...

Page 67: ...e with the coolant temperature warning lamp alight you may have engine failure Info If you hear unusual noises while riding stop immediately switch off the engine and contact an authorized KTM worksho...

Page 68: ...the brakes Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a dirty or wet brake system by riding and braking gently Warning Danger of accidents...

Page 69: ...ABS is enabled you can achieve maximum braking power even on low grip surfaces such as sandy wet or slippery terrain without locking of the wheels Warning Danger of accidents Locking of the wheels due...

Page 70: ...them Note Material damage The vehicle may be damaged by incorrect procedure when parking Significant damage may be caused if the vehicle rolls away or falls over The components for parking the vehicl...

Page 71: ...s only Park the motorcycle on a firm surface Swing the side stand forward with your foot as far as it will go and lean the vehicle on it Lock the steering p 27 9 7 Transport Note Danger of damage The...

Page 72: ...rfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel...

Page 73: ...danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system L02129 10 Switch off the engine Open the filler cap p 28 Fill the fuel tank with fuel up to th...

Page 74: ...ange the engine oil and oil filter and clean the oil screens p 151 Check the brake discs p 103 Check the front brake linings p 106 Check the rear brake linings p 109 Check the tire condition p 120 Che...

Page 75: ...es for damage and routing without sharp bends Check the valve clearance Check the valve clearance change the spark plugs Change the front brake fluid Change the rear brake fluid Check the steering hea...

Page 76: ...earing Check the wheel bearings Grease all moving parts e g side stand hand lever chain and check for smooth operation Check all hoses e g fuel cooling bleeder drainage etc and sleeves for cracking le...

Page 77: ...e spring operation on the shock absorber The best spring preload setting is achieved when it is set for the weight of the rider and that of any baggage and a passenger thus ensuring an ideal compromis...

Page 78: ...ut holding the threaded rod Adjust the shift lever by turning shift rod Guideline Shift rod adjustment range 150 162 mm 5 91 6 38 in Info Make the same adjustments on both sides At least five screw th...

Page 79: ...11 TUNING THE CHASSIS 77 Tighten nut holding the threaded rod Guideline Nut shift rod M6LH 10 Nm 7 4 lbf ft Check the shift lever to ensure it is functioning properly and can move freely...

Page 80: ...wheel stand Insert the adapter in the rear wheel stand Bushing kit for lifting gear 90229955044 Universal V adapter 61029955244 Rear wheel stand 61029055400 Stand the motorcycle upright align the lif...

Page 81: ...ean the vehicle on the side stand 12 3 Raising the motorcycle with the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even...

Page 82: ...9055500 Info Always raise the rear of the motorcycle first Raise the front of the motorcycle 12 4 Taking the motorcycle off of the front wheel stand Note Danger of damage The parked vehicle may roll a...

Page 83: ...the motorcycle off of the rear wheel stand p 78 12 5 Removing the front rider s seat M00454 10 Insert the ignition key in seat lock and turn it clockwise Raise the rear of the front rider s seat pull...

Page 84: ...the fuel tank push the front rider s seat forward and lower at the rear Catch engages in the recess Check that the front rider s seat is correctly mounted 12 7 Removing the passenger seat Preparatory...

Page 85: ...ighten screw with the washer Guideline Screw passenger seat M6 7 Nm 5 2 lbf ft Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly After mou...

Page 86: ...reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs f...

Page 87: ...ear wheel stand p 78 12 11 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain is too taut the components of the secondary power transmission c...

Page 88: ...g guard press the chain upward toward the swingarm and determine chain tension Info The upper chain section must be taut Chain wear is not always even so you should repeat this measurement at differ e...

Page 89: ...on and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme cases If the chain is too loos...

Page 90: ...o that the markings on the left and right chain adjusters are in the same position relative to the reference marks The rear wheel is then correctly aligned Info The upper chain section must be taut Ch...

Page 91: ...ain rear sprocket and engine sprocket 100132 10 Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the power set Info The engine sprocket rea...

Page 92: ...20 chain links in the lower chain section Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance at the longest chain section 301 6 mm...

Page 93: ...ard has lost material due to wear to the extent that in area the drilled hole of screw is visible from above Change the chain sliding guard Check that the chain sliding guard is firmly seated If the c...

Page 94: ...12 SERVICE WORK ON THE CHASSIS 92 M00450 10 Main work Pull loop toward the rear Pull battery cover forward and remove toward the top...

Page 95: ...pull toward the rear The battery cover engages with an audible click Check the battery cover is seated correctly Finishing work Mount the front rider s seat p 82 12 16 Removing the front spoiler Prep...

Page 96: ...12 SERVICE WORK ON THE CHASSIS 94 L02257 11 Remove screw L02263 12 Remove screws G01721 13 Remove screw Remove screw Take off the front spoiler...

Page 97: ...and tighten screw Guideline Screw front spoiler retaining bracket rear on engine M6 6 Nm 4 4 lbf ft Mount and tighten screw Guideline Screw front spoiler retaining bracket rear on engine M6 6 Nm 4 4...

Page 98: ...ighten screw Guideline Screw front spoiler right on footrest bracket M6 6 Nm 4 4 lbf ft L02258 12 Mount and tighten screws Guideline Screw front spoiler M6 6 Nm 4 4 lbf ft Finishing work Install the l...

Page 99: ...12 SERVICE WORK ON THE CHASSIS 97 12 18 Removing the left side cover S00781 10 Remove screws Remove screws Pull off holding lug in area M00456 10 Remove expanding rivet...

Page 100: ...12 SERVICE WORK ON THE CHASSIS 98 L02260 10 Swing the side cover outward Pull hose out of hose guide Take off the side cover 12 19 Installing the left side cover L02260 11 Position hose in hose guide...

Page 101: ...tighten screws Guideline Screw side cover M6 6 Nm 4 4 lbf ft Push on the side cover in area The holding lug engages in the drilled hole on the front spoiler Mount and tighten screws Guideline Screw s...

Page 102: ...12 SERVICE WORK ON THE CHASSIS 100 12 20 Removing the right side cover S00782 10 Remove screws Remove screws Pull off holding lug in area M00455 10 Remove expanding rivet Take off the side cover...

Page 103: ...ide cover Mount and tighten screws Guideline Screw side cover M6 6 Nm 4 4 lbf ft Push on the side cover in area The holding lug engages in the drilled hole on the front spoiler Mount and tighten screw...

Page 104: ...ied tire air pressure Service work and repairs must be performed professionally Your authorized KTM workshop will be glad to help The ABS is a safety system that prevents locking of the wheels when dr...

Page 105: ...for example when making wheelies or if the rear wheel spins This causes the ABS to switch off To reenable the ABS the vehicle must be stopped and the ignition switched off The ABS is reenabled when t...

Page 106: ...elow the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Dan...

Page 107: ...les If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake flu...

Page 108: ...spilt brake fluid immediately with water 13 5 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediatel...

Page 109: ...ear brake fluid level Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings C...

Page 110: ...ystem and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep ou...

Page 111: ...from a sealed container Preparatory work Check the rear brake linings p 109 M00459 10 Main work Stand the vehicle upright Remove screw cap with membrane Add brake fluid to level Brake fluid DOT 4 DOT...

Page 112: ...r minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings Check the brake linings for damage and cracking If there is wear or tea...

Page 113: ...2 in If the free travel does not meet specifications Adjust the free travel of the foot brake lever p 111 Reconnect spring 13 10 Adjusting the free travel of the foot brake lever Warning Danger of acc...

Page 114: ...11 Disconnect 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...

Page 115: ...out of the hole Loosen screw and screws Unscrew screw about 6 turns and press your hand on the screw to push the wheel spindle out of the axle clamp Remove screw Warning Danger of accidents Reduced br...

Page 116: ...ep the brake discs free of oil and grease and clean them with brake cleaner when necessary L02183 11 Main work Remove spacers Check the wheel bearing for damage and wear If the wheel bearing is damage...

Page 117: ...Screw wheel speed sensor holder M6 7 Nm 5 2 lbf ft Mount and tighten screws Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure...

Page 118: ...ing the rear wheel withdraw wheel spindle with the washer and chain adjuster Push the rear wheel forward as far as possible and take the chain off the rear sprocket Warning Danger of accidents Reduced...

Page 119: ...ssure point is reached Main work Check the rear hub rubber dampers p 118 L02151 10 Remove spacers Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the rear wh...

Page 120: ...adjusters must be in the same position relative to the reference marks Nut rear wheel spindle M14x1 5 90 Nm 66 4 lbf ft Position wheel speed sensor in the drill hole Mount and tighten screw Guideline...

Page 121: ...n Change all rubber dampers in the rear hub L02152 10 Lay the read wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub To check the play hold the rear wh...

Page 122: ...e vehicle Warning Danger of accidents Non approved or non recommended tires and wheels impact the handling characteristic Only use tires wheels approved by KTM with the corresponding speed index Info...

Page 123: ...commends that the tires are changed regardless of the actual wear at the latest after 5 years If a tire is more than 5 years old Change the tires 14 7 Checking the tire air pressure Info Low tire air...

Page 124: ...14 WHEELS TIRES 122 If the tire air pressure does not meet specifications Correct the tire air pressure Mount the dust cap...

Page 125: ...cid and battery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the...

Page 126: ...ed battery or without a battery In both cases electrical components and safety devices can be damaged The vehi cle is therefore no longer roadworthy 15 2 Installing the battery L02157 10 Main work Pos...

Page 127: ...Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid an...

Page 128: ...rging current shortens the battery s service life If the charging current charging voltage or charging time is exceeded electrolyte escapes through the safety valves This reduces the battery capacity...

Page 129: ...tor With this device you cannot overcharge the battery Info Never remove lid Switch off the battery charger after charging and disconnect from the battery Guideline The charge current charge voltage a...

Page 130: ...of the ABS The third fuse which protects the ABS control unit is located in the fuse box Preparatory work Switch off all power consumers and the engine Remove the front rider s seat p 81 Remove the ba...

Page 131: ...ap and remove fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never bypass or repair fuses Use spare fuses with...

Page 132: ...p 81 Remove the battery cover p 91 L02275 11 Main work Open fuse box cover Remove the defective fuse Guideline Fuse 1 30 A main fuse Fuse 2 15 A combination instrument alarm system optional Fuse 3 15...

Page 133: ...prescribed amperage Never bypass or repair fuses Use spare fuses with the correct rating only Fuse 75011088010 p 177 Fuse 75011088015 p 177 Fuse 75011088030 p 177 Tip Replace the spare fuse in the fu...

Page 134: ...and keep it free of grease before mounting Preparatory work Switch off all power consumers and switch off the engine L02161 10 Main work Turn socket counterclockwise Pull the socket with low beam bul...

Page 135: ...that the lighting is functioning properly 15 7 Changing the high beam bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflect...

Page 136: ...housing Disconnect the socket with the high beam bulb from connector and remove Connect the new socket with the high beam bulb to the connector High beam H9 socket PGJ19 5 p 177 L02165 10 Position the...

Page 137: ...n Position the vehicle perpendicular to the wall at a distance from the wall and switch on the low beam Guideline Distance 5 m 16 ft The rider with luggage and passenger if applicable now mounts the m...

Page 138: ...sition the vehicle perpendicular to the wall at a distance from the wall and switch on the high beam Guideline Distance 5 m 16 ft The rider with luggage and passenger if applicable now mounts the moto...

Page 139: ...counterclockwise to reduce the headlight range Finishing work Check the low beam headlight adjustment p 135 15 11 Adjusting the headlight range of the high beam L02163 10 Main work Adjust the beam di...

Page 140: ...he cooling system is regulated by a valve in radiator cap Heat expansion causes excess coolant to flow into compensating tank When the temperature falls this surplus coolant is sucked back into the co...

Page 141: ...so reduce the cooling effect 16 2 Checking the coolant level in the compensating tank Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remo...

Page 142: ...contaminated with coolant Keep coolant out of reach of children Condition The engine is cold The radiator is completely full S00783 10 Stand the motorcycle upright on a horizontal surface Check the co...

Page 143: ...If contact occurs with the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed con tact a physician im...

Page 144: ...eze does not meet specifications Correct the coolant antifreeze Check the coolant level in the radiator The radiator must be completely filled If the coolant level does not meet specifications Correct...

Page 145: ...alth hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas...

Page 146: ...the skin eyes or clothing If contact occurs with the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowe...

Page 147: ...must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with s...

Page 148: ...g them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective...

Page 149: ...16 COOLING SYSTEM 147 Install the right side cover p 101...

Page 150: ...pecifications Adjust the play in the throttle cable p 149 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always...

Page 151: ...e clutch lever for smooth operation Move the handlebar to the straight ahead position Pull the clutch lever until resistance is perceptible and determine the play in the clutch lever Clutch lever play...

Page 152: ...utch cable 17 4 Adjusting the clutch cable play L02155 10 Move the handlebar to the straight ahead position Push back sleeve Loosen lock nut Adjust the play in the clutch level by turning adjusting sc...

Page 153: ...l is below the marking Add the engine oil p 154 When the engine oil level is above the marking Correct the engine oil level 18 2 Changing the engine oil and oil filter cleaning the oil screens Warning...

Page 154: ...k Place a suitable container under the engine Remove oil drain plug with the O ring Remove oil screen with the O ring Remove screw plug with oil screen Completely drain the engine oil Thoroughly clean...

Page 155: ...ely drain the engine oil Thoroughly clean the parts and sealing surface L02271 10 Insert oil filter Lubricate the O ring of the oil filter cover Mount oil filter cover Mount and tighten the screws Gui...

Page 156: ...unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction s...

Page 157: ...ecommended changing the engine oil when necessary Install and tighten the oil filler plug with the O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconscious...

Page 158: ...malfunctions or destroy these parts Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in...

Page 159: ...ue to a wet or dirty brake sys tem Clean or dry a dirty or wet brake system by riding and braking gently After cleaning ride the vehicle a short distance until the engine warms up Info The heat produc...

Page 160: ...for winter operation Info If the motorcycle is used in the winter salt can be expected on the roads Precautions need to be taken against road salt corrosion If the vehicle was operated in road salt c...

Page 161: ...ll other bright and zinc plated parts except for the brake discs with a wax based corrosion inhibitor Info Corrosion inhibitor is not permitted to come in contact with the brake discs as this would gr...

Page 162: ...for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 187 Refuel p 70 Clean the motorcycle p 156 Change the engine oil and oil filter and clean the oil screen...

Page 163: ...ng the engine for a short time only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 20 2 Preparing for use af...

Page 164: ...t Operating error Go through the steps of starting the engine p 61 Fault in fuel injection system Read out the fault memory using the KTM diag nostics tool Engine has too little power Air filter is ve...

Page 165: ...Malfunction in ABS Read out the ABS fault memory using the KTM diagnostics tool High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary Engine oil level...

Page 166: ...ck the open circuit current The combination instrument shows nothing on the display Fuse 7 is blown Change the fuses of individual power consumers p 130 Set the clock p 54 Speedometer in combination i...

Page 167: ...warning lamp MIL 09 Engine diagnostic warning lamp MIL flashes 9x short Error level condition Manifold absolute pressure sensor input signal too low Manifold absolute pressure sensor input signal too...

Page 168: ...cuit fault Fuel tank sensor short circuit to ground Fuel tank sensor short circuit to plus Blink code engine diagnostic warning lamp MIL 15 Engine diagnostic warning lamp MIL flashes 1x long 5x short...

Page 169: ...dition Engine diagnosis warning lamp MIL circuit fault Engine diagnosis warning lamp MIL short circuit to ground Engine diagnosis warning lamp MIL short circuit to plus Blink code engine diagnostic wa...

Page 170: ...short Error level condition Travel speed sensor measurement range or power problem Blink code engine diagnostic warning lamp MIL 24 Engine diagnostic warning lamp MIL flashes 2x long 4x short Error le...

Page 171: ...evel condition Sensor B reference voltage input signal too low Sensor B reference voltage input signal too high Blink code engine diagnostic warning lamp MIL 33 Engine diagnostic warning lamp MIL flas...

Page 172: ...ensor heater circuit fault Lambda sensor heater short circuit to ground or open circuit Lambda sensor heater input signal too high Blink code engine diagnostic warning lamp MIL 49 Engine diagnostic wa...

Page 173: ...ce intake cold 0 08 0 12 mm 0 0031 0 0047 in Valve clearance exhaust cold 0 13 0 17 mm 0 0051 0 0067 in Crankshaft bearing 2 slide bearings Conrod bearing Sleeve bearing Pistons Cast light alloy Pisto...

Page 174: ...04 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 450 1 550 rpm Starting aid Electric starter 23 2 Engine tightening torques Oil nozzle M5 6 Nm 4 4 lbf ft Loctite...

Page 175: ...case M6x35 12 Nm 8 9 lbf ft Loctite 243 Screw engine case M6x75 12 Nm 8 9 lbf ft Screw engine sprocket M6 11 Nm 8 1 lbf ft Screw engine vent plate M6 10 Nm 7 4 lbf ft Loctite 243 Screw freewheel gear...

Page 176: ...lancer shaft gear M8 25 Nm 18 4 lbf ft Loctite 243 Screw return spring quick shifter M8 20 Nm 14 8 lbf ft Loctite 243 Stud exhaust flange M8 22 Nm 16 2 lbf ft Screw conrod bearing M8x1 34 Nm 25 1 lbf...

Page 177: ...ver M24x1 5 10 Nm 7 4 lbf ft Nut balancer shaft gear M28x1 5 60 Nm 44 3 lbf ft Loctite 243 23 3 Capacities 23 3 1 Engine oil Engine oil 1 7 l 1 8 qt Engine oil SAE 15W 50 p 185 23 3 2 Coolant Coolant...

Page 178: ...230 mm 9 06 in Brake discs wear limit Front 4 5 mm 0 177 in Rear 3 6 mm 0 142 in Tire air pressure solo Front 2 0 bar 29 psi Rear 2 0 bar 29 psi Tire air pressure with passenger full payload Front 2 0...

Page 179: ...ectrical system 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 Low beam H11 Sockel...

Page 180: ...e section under http www ktm com 23 7 Fork Fork part number 90801000000 Fork WP Suspension Fork length 736 mm 28 98 in Fork oil 460 ml 15 55 fl oz Fork oil SAE 4 48601166S1 p 186 23 8 Shock absorber S...

Page 181: ...Remaining nuts chassis M5 5 Nm 3 7 lbf ft Remaining screws chassis M5 5 Nm 3 7 lbf ft Screw ABS hose clamp M5 5 Nm 3 7 lbf ft Screw anti rotation lock handlebar stub M5 4 Nm 3 lbf ft Screw battery co...

Page 182: ...7 Nm 5 2 lbf ft Screw air filter box on frame M6 7 Nm 5 2 lbf ft Screw battery compartment M6 6 Nm 4 4 lbf ft Screw brake fluid container front brake M6 8 Nm 5 9 lbf ft Screw brake fluid reservoir hol...

Page 183: ...ining bracket rear on engine M6 6 Nm 4 4 lbf ft Screw front spoiler right on footrest bracket M6 6 Nm 4 4 lbf ft Screw fuel tank trim M6 6 Nm 4 4 lbf ft Screw ground cable on frame M6 7 Nm 5 2 lbf ft...

Page 184: ...sensor holder M6 7 Nm 5 2 lbf ft Screw windshield M6 7 Nm 5 2 lbf ft Fitting engine mounting bracket M8 48 Nm 35 4 lbf ft Remaining nuts chassis M8 30 Nm 22 1 lbf ft Remaining screws chassis M8 25 Nm...

Page 185: ...43 Remaining nuts chassis M10 50 Nm 36 9 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Fitting shock absorber bottom M10x1 25 50 Nm 36 9 lbf ft Nut turn signal M10x1 25 6 Nm 4 4 lbf ft Screw f...

Page 186: ...23 TECHNICAL DATA 184 Nut steering head M30x1 Step 1 55 Nm 40 6 lbf ft 2nd stage loosen counter clockwise 2 turns Step 3 5 Nm 3 7 lbf ft...

Page 187: ...AKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Only use high quality coolant with corrosion inhibitor for aluminum motors even in countries with high temperatures Using inferior a...

Page 188: ...4 Guideline Use only oils that comply with the specified standards see specifications on the container and that possess the corresponding proper ties Super unleaded ROZ 95 RON 95 PON 91 Standard class...

Page 189: ...Chain Clean Chain lube for road use Guideline Recommended supplier Motorex Chainlube Road Fuel additive Recommended supplier Motorex Fuel Stabilizer Long life grease Recommended supplier Motorex Bike...

Page 190: ...ex Moto Polish 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 Recommend...

Page 191: ...vice intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated wit...

Page 192: ...27 INDEX OF SPECIAL TERMS 190 ABS ABS Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces...

Page 193: ...28 LIST OF ABBREVIATIONS 191 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 194: ...rompt intervention Active driving aids are also represented by yellow or orange symbols The general warning lamp lights up yellow An operating safety warning message was detected This is also shown in...

Page 195: ...ding 105 rear brake adding 108 Brake fluid level front brake checking 104 rear brake checking 107 Brake linings front brake checking 106 rear brake checking 109 Brakes 66 Brakes applying 66 C Capacity...

Page 196: ...speed menu 46 service range menu 49 total distance menu ODO 51 warning notes 36 Coolant draining 144 Coolant level checking 141 compensating tank checking 139 compensating tank correcting 143 Cooling...

Page 197: ...ging 133 High beam flasher button 24 High beam headlight adjustment checking 136 Horn button 23 I Ignition lock 26 Implied warranty 14 Indicator lamps 40 K Key number 21 Kilometers or miles adjusting...

Page 198: ...r use 60 Protective clothing 12 R Rear hub rubber dampers checking 118 Rear sprocket checking 89 Rear wheel installing 117 removing 116 Riding 63 starting off 63 Right side cover installing 101 removi...

Page 199: ...engine tightening torques 172 fork 178 shock absorber 178 tires 178 Throttle grip 23 Time adjusting 54 Tire air pressure checking 121 Tire condition checking 120 Tool set 30 Transport 69 Troubleshoot...

Page 200: ...3213408en 3213408en 11 2015 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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