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SERVICE WORK ON THE ENGINE

184

19.1

Checking the engine oil level

Info

Oil consumption depends on the riding style and the operating conditions.

Condition

The engine is at operating temperature.

Preparatory work

–

Stand the motorcycle upright on a horizontal surface.

401696-11

Main work

–

Check the engine oil level in the engine oil level viewer.

Info

After switching off the engine, wait one minute before checking the level.

The engine oil level should be in the upper area

of the engine oil level viewer.

» When the engine oil level is in area

of the engine oil level viewer:

–

Do not add engine oil.

» When the engine oil level is in area

of the engine oil level viewer:

–

Engine oil can be added.

» When the engine oil level is in area

of the engine oil level viewer:

–

Add engine oil. (

p. 189)

Содержание 1190 ADVENTURE R

Страница 1: ...OWNER S MANUAL 2014 1190 Adventure R USA Art no 3213108en...

Страница 2: ......

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

Страница 4: ...ccording to the international quality management standard ISO 9001 KTM uses quality assurance processes that lead to the maximum possible quality of the products Issued by T V Management Service KTM S...

Страница 5: ...24 4 1 View of vehicle front left side vehicle differs slightly from photo 24 4 2 View of vehicle rear right side vehicle differs slightly from photo 26 5 SERIAL NUMBERS 28 5 1 Chassis number 28 5 2...

Страница 6: ...orites 56 7 9 7 Settings 56 7 9 8 Warnings 57 7 9 9 Heat Grip optional 57 7 9 10 MTC ABS 58 7 9 11 Drive Mode 58 7 9 12 Menu overview 60 7 9 13 Language 61 7 9 14 Distance 62 7 9 15 Temp 62 7 9 16 Vol...

Страница 7: ...e rebound damping of the shock absorber 102 12 9 Adjusting the spring preload of the shock absorber 103 13 SERVICE WORK ON THE CHASSIS 105 13 1 Raising the vehicle with the center stand 105 13 2 Remov...

Страница 8: ...158 16 5 Changing the main fuse 162 16 6 Changing the fuses in the fuse box 164 16 7 Removing the headlight mask with the headlight 166 16 8 Refitting the headlight mask with the headlight 167 16 9 Ch...

Страница 9: ...201 23 3 Capacities 205 23 3 1 Engine oil 205 23 3 2 Coolant 205 23 3 3 Fuel 205 23 4 Chassis 205 23 5 Electrical system 207 23 6 Tires 208 23 7 Fork 208 23 8 Shock absorber 209 23 9 Chassis tighteni...

Страница 10: ...standing In the interest of your own safety have these jobs performed by an authorized KTM workshop There your motorcycle will be optimally cared for by specially trained experts using the specialist...

Страница 11: ...oads in the homologated version 2 2 Safety advice A number of safety instructions need to be followed to operate the vehicle safely Therefore read this manual carefully The safety instruc tions are hi...

Страница 12: ...hat is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken Note Id...

Страница 13: ...11...

Страница 14: ...2 SAFETY ADVICE 12 2 4 Overview of labels 500295 10...

Страница 15: ...sion tuning 2 Canada type label 3 Information on starting up 4 Information on emission control 5 Information on chain tension 6 Information on noise emission 7 USA type label 8 Technical Information 5...

Страница 16: ...2 SAFETY ADVICE 14 500297 01 Canada type label 700210 01 Information on starting up...

Страница 17: ...2 SAFETY ADVICE 15 500299 01 Information on emission control 500304 01 Information on chain tension...

Страница 18: ...2 SAFETY ADVICE 16 500301 01 Information on noise emission 500302 01 USA type label...

Страница 19: ...nc To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 888 327 4236 or visit the website www nhtsa dot gov or write to NHTSA Headquarters 1200 New Jersey Avenue SE West Buildin...

Страница 20: ...ictorin Saint Bruno QC J3V 6B7 Phone 450 441 4451 x 4250 www ktmcanada com Different rights may apply according to national or regional legislation 2 9 Tampering warning Tampering with the noise contr...

Страница 21: ...ness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Warnin...

Страница 22: ...elf locking screws and nuts seals and seal rings O rings pins lock washers must be replaced by new parts Where thread lockers are used on screw connections e g Loctite follow the instructions for use...

Страница 23: ...then 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...

Страница 24: ...d auxiliary substances such as fuel and lubricants as specified in the Owner s Manual 3 3 Spare parts accessories For your own safety only use spare parts and accessory products that are approved and...

Страница 25: ...these exactly you will ensure a much longer service life for your motorcycle 3 5 Figures The figures contained in the manual may depict special equipment In the interest of clarity some components may...

Страница 26: ...4 VIEW OF VEHICLE 24 4 1 View of vehicle front left side vehicle differs slightly from photo 500293 10...

Страница 27: ...38 2 Clutch lever p 32 3 Tool set p 43 4 Grab handles p 44 5 Luggage rack plate p 44 6 Seat lock p 43 7 Passenger footrests p 45 8 Center stand p 47 9 Rider footrests p 71 10 Shift lever p 45 11 Side...

Страница 28: ...4 VIEW OF VEHICLE 26 4 2 View of vehicle rear right side vehicle differs slightly from photo 500294 10...

Страница 29: ...adjustment 4 Fork rebound adjustment 5 Emergency OFF switch p 36 6 Electric starter button p 37 7 Hand brake lever p 32 8 Storage compartment 9 Cooling system compensating tank 10 Foot brake lever p 7...

Страница 30: ...The chassis number 1 is stamped on the bottom right of the frame behind the steering head The chassis number is also shown on the type label 5 2 Type label 500305 10 Type label USA 1 is affixed to the...

Страница 31: ...1 The key number Code 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 Use the orange programming key to activate and dea...

Страница 32: ...IAL NUMBERS 30 5 4 Engine number S00261 10 The engine number 1 is stamped on the right side of the engine 5 5 Fork part number S00306 10 The fork part number 1 is stamped on the inner side of the fork...

Страница 33: ...5 SERIAL NUMBERS 31 5 6 Shock absorber part number S00264 10 The shock absorber part number 1 is stamped on the upper part of the shock absorber...

Страница 34: ...elf adjusting 6 2 Hand brake lever S00215 10 The hand brake lever 1 is fitted on the right side of the handlebar The hand brake lever is used to activate both the front brake and rear brake at the sam...

Страница 35: ...6 4 Switch on the left side of the handlebar 6 4 1 Combination switch The combination switch is fitted on the left side of the handlebar S00224 10 Overview of the left combination switch 1 Light switc...

Страница 36: ...4 3 Hazard warning flasher switch 602606 10 The hazard warning flasher switch 1 is fitted on the combination switch on the left The hazard warning flasher is used to indicate emergency situations Info...

Страница 37: ...signal switch S00217 10 The turn signal switch 1 is fitted on the combination switch on the left Possible states Turn signal off Press the turn signal switch Turn signal left on Turn signal switch pre...

Страница 38: ...ight side of the handlebar 6 5 1 Emergency OFF switch S00220 10 The emergency OFF switch 1 is fitted on the right side of the handlebar Possible states Emergency OFF switch off In this position the ig...

Страница 39: ...e clamp Info The ignition may only be switched on using a black ignition key With the orange programming key you can activate or deactivate the black ignition key Possible states Ignition off OFF In t...

Страница 40: ...ever attach multiple ignition keys to a single key ring this may cause mutual interference A lost black ignition key must be deactivated to prevent unauthorized persons from operat ing the vehicle The...

Страница 41: ...must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean conta...

Страница 42: ...reakage To take pressure off of the ignition key push down on the filler cap Damaged igni tion keys must be replaced Turn ignition key 2 clockwise Fold open filler cap 3 6 10 Closing the filler cap S0...

Страница 43: ...ediately clean contaminated areas on the skin with soap and water Remove ignition key 2 and close cover 3 6 11 Fuel cocks S00341 10 A fuel cock 1 is located on each side of the fuel tank Info The fuel...

Страница 44: ...Opening the storage compartment S00226 10 Press button 1 in the direction of the arrow and lift the cover at the same time 6 13 Closing the storage compartment S00226 11 Press down cover 1 until the l...

Страница 45: ...14 Seat lock S00238 10 The seat lock 1 is located on the left side of the vehicle It can be unlocked using the ignition key 6 15 Tool set S00235 10 The tool set 1 is located in the storage compartment...

Страница 46: ...The luggage rack plate 1 is located behind the seat The base plate of a luggage system optional can be attached to the luggage rack plate The luggage rack plate may not be loaded with more than the sp...

Страница 47: ...ootrests can be folded up and down Possible states Passenger footrests folded up For operation without a passenger Passenger footrests folded down For operation with a passenger 6 19 Shift lever S0023...

Страница 48: ...d for parking the motorcycle Info The side stand must be folded up during motorcycle use The side stand is coupled with the safety start system see the instructions in the Stopping parking chapter Pos...

Страница 49: ...6 CONTROLS 47 6 21 Center stand S00258 10 In addition to the side stand the vehicle is equipped with a center stand 1...

Страница 50: ...trument is activated when the ignition is switched on Info The brightness of the displays is controlled by a brightness sensor in the combina tion instrument Test The segment display the indicator lam...

Страница 51: ...If the General warning lamp lights up among the indicator lamps p 50 the corre sponding message appears in the matrix display The Set button is used to confirm receipt of the information and the messa...

Страница 52: ...lay The left turn signal lamp flashes green simultaneously with the turn signal The left turn signal is switched on The idle indicator lamp lights up green The transmission is shifted to idle The righ...

Страница 53: ...w Switch off the engine immediately Contact an authorized KTM workshop Engine oil level The engine oil level is too low Check the engine oil level and correct it Tire air pressure The tire pressure is...

Страница 54: ...or lights up when the transmission should be shifted In the Shift Light menu the engine speed for the shift warning light can be set The shift warning light flashes over RPM1 and lights up permanently...

Страница 55: ...found in the service schedule 7 9 Matrix display menu 7 9 1 Favorites 401988 01 Press the UP or DOWN button until the Favorites menu appears on the matrix display Pressing the SET button opens the me...

Страница 56: ...range with the fuel reserve Press and hold the button for 3 5 seconds All entries in the Trip 1 menu are cleared 7 9 3 Trip 2 401825 01 Press the UP or DOWN button until the Trip 2 menu appears on th...

Страница 57: ...the battery voltage Oil Temp indicates the engine oil temperature 7 9 5 TPMS optional 401845 01 Press the UP or DOWN button until the TPMS menu appears on the matrix display Guideline Tire air pressur...

Страница 58: ...WN button to select the menu Press the SET button to set the menu for quick selection In the Set Favorites menu the Favorites menu can be configured 7 9 7 Settings 401841 01 Condition The vehicle is s...

Страница 59: ...n to navigate through the warnings In the Warnings menu warnings that occurred are displayed and stored until they are no longer active 7 9 9 Heat Grip optional 401838 01 Press the UP or DOWN button u...

Страница 60: ...vated ABS can intervene on both wheels 7 9 11 Drive Mode 401829 01 Press the UP or DOWN button until the Drive Mode menu appears on the matrix display Pressing the SET button opens the menu Use the UP...

Страница 61: ...59...

Страница 62: ...7 COMBINATION INSTRUMENT 60 7 9 12 Menu overview 401992 01...

Страница 63: ...messages are present Heat Grip optional MTC ABS Drive Mode 7 9 13 Language 401842 10 Condition The vehicle is stationary Press the UP or DOWN button until the Settings menu appears on the matrix displ...

Страница 64: ...matrix dis play Pressing the SET button again sets the unit of measure Select kilometers km or miles mi for the distance 7 9 15 Temp 401842 12 Condition The vehicle is stationary Press the UP or DOWN...

Страница 65: ...lay Pressing the SET button again sets the unit of measure Select liters or gallons for the fuel consumption display 7 9 17 Pressure 401842 14 Condition The vehicle is stationary Press the UP or DOWN...

Страница 66: ...e UP or DOWN button to navigate through the menu Use the SET button to set the time and date If the battery was disconnected the time and date must be set in the matrix display 7 9 19 Fuel Cons 401842...

Страница 67: ...me running light 7 9 21 Shift Light 401846 01 Condition The vehicle is stationary Press the UP or DOWN button until the Settings menu appears on the matrix display Pressing the SET button opens the me...

Страница 68: ...be activated Info This function is not available in this model 7 9 23 Heat Grips 401842 21 Condition The vehicle is stationary Press the UP or DOWN button until the Settings menu appears on the matrix...

Страница 69: ...e handlebar position x Warning Danger of accidents Handlebar breakage If the handlebar is bent or straightened it will cause material fatigue and the handlebar can break Always replace handlebar 30808...

Страница 70: ...bar supports evenly Position the handlebar Info Make sure cables and wiring are positioned correctly Position the handlebar clamps Mount and evenly tighten screws 1 Guideline Screw handlebar clamp M8...

Страница 71: ...8 ERGONOMICS 69 S00247 10 Move the wind shield in the required position S00342 11 Lock clamping lever 1 by pushing in the direction of the arrow...

Страница 72: ...w counterclockwise to decrease the distance between the clutch lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make a...

Страница 73: ...two positions Possible states Rider footrests low A Rider footrests high B 8 7 Adjusting the footrests x Info The operations are the same for the left and right sides S00248 10 Remove cotter pin 1 wit...

Страница 74: ...NOMICS 72 S00249 10 Remove screws 5 S00250 10 Adjust the footrest bracket to the desired position S00249 10 Mount and tighten screws 5 Guideline Screw front footrest bracket M8 25 Nm 18 4 lbf ft Locti...

Страница 75: ...in front of the right footrest The rear brake is activated using the foot brake lever 8 9 Adjusting the basic position of the foot brake lever x Warning Danger of accidents Brake system failure If th...

Страница 76: ...ual requirements turn ball joint 4 accordingly Info The range of adjustment is limited The screw must be screwed into the ball joint by at least 5 turns Hold ball joint 4 and tighten nut 2 Guideline R...

Страница 77: ...distance A between the upper edge of your boot and the shift lever Distance between shift lever and upper edge of boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the bas...

Страница 78: ...r 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 shi...

Страница 79: ...crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control...

Страница 80: ...ndover Before your first trip read the entire Owner s Manual carefully Get to know the controls Adjust the motorcycle to your requirements as described in the Ergonomics chapter Get used to handling t...

Страница 81: ...cure suitcase and tank rucksack according to the manufacturer s instructions Warning Danger of accidents Unstable handling characteristics at high speed Adapt your speed according to your payload Ride...

Страница 82: ...A hot exhaust system can burn baggage Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system If you are carrying baggage make sure it is fixed firmly as close a...

Страница 83: ...37 Check the front brake linings p 136 Check the rear brake linings p 140 Check that the brake system is functioning properly Check the coolant level in the compensating tank p 179 Check the chain for...

Страница 84: ...damaged Never operate the vehicle with a discharged battery or without a battery Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always...

Страница 85: ...smission is in neutral or if the clutch lever is pulled when a gear is engaged If the side stand is folded out and you shift into gear the engine stops Remove the motorcycle from the center stand or s...

Страница 86: ...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...

Страница 87: ...hicle as usual before preparing for use Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never ride the vehicle without an air filter since dust and di...

Страница 88: ...and accelerate very carefully To shift down brake if necessary and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the t...

Страница 89: ...and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Failure of brake system If the foot brake lever is not released the brake linings drag continu...

Страница 90: ...e road condi tions and your riding ability When braking release the throttle and apply the front and rear brakes at the same time Info When ABS is enabled you can achieve maximum braking power even on...

Страница 91: ...ch as exhaust system radiator engine shock absorber and the brake system Allow these components to cool down before starting work on them Note Danger of damage The parked vehicle may roll away or fall...

Страница 92: ...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 key the emergency OFF switch is...

Страница 93: ...ar open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel t...

Страница 94: ...elp Only refuel with clean fuel that meets the specified standards Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water...

Страница 95: ...00 km 620 mi Read out the trouble code memory using the KTM diagnostics tool x Check the fuel pressure x Check the functioning of the electrical equipment Change the engine oil and filter clean the oi...

Страница 96: ...sion p 109 Check the brake lines for damage and leakage Check the brake fluid level of the front brake p 134 Check the coolant level in the compensating tank p 179 Change the air filter Clean the air...

Страница 97: ...setting p 172 Final check Check the vehicle for roadworthiness and take a test ride Read out the error memory after the test ride using the KTM diagnostics tool x Check the CO adjustment with the KTM...

Страница 98: ...earing for play x Grease all moving parts e g side stand hand lever chain and check for smooth operation x Check all hoses e g fuel cooling bleeder drainage etc and sleeves for cracking leaks and inco...

Страница 99: ...uidelines are not adhered to the riding characteristics could deteriorate particularly at high speeds 12 2 Adjusting the compression damping of the fork Info The hydraulic compression damping determin...

Страница 100: ...ork Info The hydraulic rebound damping determines the fork suspension behavior S00263 10 Turn the red adjusting screw 1 all the way clockwise Info Adjusting screw 1 is located at the upper end of the...

Страница 101: ...counterclockwise to reduce damping 12 4 Adjusting the spring preload of the fork S00260 10 Turn adjusting screws 1 counterclockwise all the way Info Make the same adjustment on both fork legs Turn clo...

Страница 102: ...when riding over an asphalt edge the rear wheel suspension compresses quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses m...

Страница 103: ...clicks Sport 8 clicks Full payload 8 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 12 7 Adjusting the high speed compression damping of the shock absorber Caut...

Страница 104: ...ing high speed Comfort 1 5 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce damping 12 8 Adjusting the rebound damping...

Страница 105: ...15 clicks Standard 10 clicks Sport 8 clicks Full payload 8 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 12 9 Adjusting the spring preload of the shock absorbe...

Страница 106: ...go Turn it clockwise by the number of turns corresponding to the shock absorber type and use Guideline Spring preload Comfort 4 turns Standard 4 turns Sport 4 turns Full payload 16 turns Info Turn clo...

Страница 107: ...ter stand The center stand or the frame may become damaged and the motorcycle may fall over Pull the motorcycle up onto the center stand at the grab handles S00307 10 Stand to the left of the vehicle...

Страница 108: ...e vehicle tips off of the center stand activate the front brake to stop the vehi cle from rolling away Check that the center stand is folded all the way up 13 3 Removing the seat S00241 10 Insert the...

Страница 109: ...wer the rear while pushing it for ward Insert locking pin 2 into the lock housing and push down the rear of the seat until the locking pin engages with a click Check that the seat is correctly mounted...

Страница 110: ...nd grease and clean them with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be dispo...

Страница 111: ...cases If the chain is too loose however it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine Ensure that the chain tension is correct and adjust it if nec...

Страница 112: ...bearings in the transmission 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 case...

Страница 113: ...and right chain adjusters 4 are in the same position in relation to reference marks C The rear wheel is then correctly aligned Info The upper part of the chain must be taut Chain wear is not always ev...

Страница 114: ...t Preparatory work Raise the vehicle with the center stand p 105 100132 10 Main work Check the rear sprocket and engine sprocket for wear If the rear sprocket or engine sprocket is worn Change the pow...

Страница 115: ...the chain Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance B at the longest chain section 272 mm 10 71 in If distance B is great...

Страница 116: ...iding guard Change the chain sliding guard x Check the chain sliding guard for tightness If the chain sliding guard is loose Tighten the chain sliding guard Guideline Screw chain sliding guard M5 5 Nm...

Страница 117: ...ing wear of the clutch lining disc Do not use brake fluid S00270 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 Che...

Страница 118: ...ork Raise the vehicle with the center stand p 105 400738 11 Main work Place a load on the rear of the vehicle The front wheel is not in contact with the ground Move the handlebar to the straight ahead...

Страница 119: ...ing the bottom triple clamp cover 202248 12 Remove screws 1 Plug out the horn Remove the triple clamp cover 2 13 13 Installing the bottom triple clamp cover x 202248 13 Position the triple clamp cover...

Страница 120: ...13 SERVICE WORK ON THE CHASSIS 118 13 14 Removing the front side cover 307815 10 Remove screw 1 307816 10 Remove screws 2 Remove side cover 3 Repeat the operation on the opposite side...

Страница 121: ...CHASSIS 119 13 15 Installing the front side cover 307817 10 Position the side cover in the A area under the tank cover 307818 10 Attach catch 1 and bracket 2 of the side cover to the fuel tank and po...

Страница 122: ...art M5x12 3 5 Nm 2 58 lbf ft 307816 11 Mount and tighten screws 4 Guideline Screw cover part M5x12 3 5 Nm 2 58 lbf ft Repeat the operation on the opposite side 13 16 Removing the mask spoiler x Prepar...

Страница 123: ...13 SERVICE WORK ON THE CHASSIS 121 307823 10 Main work Remove screw 1 307824 10 Remove screw 2 307825 10 Loosen holding lug 3 from the inside cover...

Страница 124: ...2 307828 10 Remove the mask spoiler laterally from the supports 307826 10 Pull the mask spoiler upward from bracket 4 307827 10 Detach connector 5 Remove the mask spoiler with the turn signal Repeat t...

Страница 125: ...E WORK ON THE CHASSIS 123 13 17 Installing the mask spoiler x 307827 11 Main work Plug in connector 1 307826 11 Position the mask spoiler in bracket 2 Info Ensure that the turn signal cable is placed...

Страница 126: ...THE CHASSIS 124 307828 11 Press the mask spoiler laterally into the supports 307825 10 Position holding lug 3 in the drill hole 307824 11 Mount and tighten screw 4 Guideline Screw mask spoiler M5x17...

Страница 127: ...ft Repeat the operation on the opposite side Finishing work Install the tank cover p 128 Install the front side cover p 119 Mount the seat p 107 13 18 Removing the front fender S00323 10 Remove holde...

Страница 128: ...ion to where the brake lines are placed Mount and tighten screws 1 Guideline Screw fender M5x12 3 5 Nm 2 58 lbf ft Mount holder 2 with the brake line on the fender 13 20 Removing the tank cover Prepar...

Страница 129: ...13 SERVICE WORK ON THE CHASSIS 127 307820 10 Remove screw 3 Remove screw 4 307821 10 Remove screw 5 307822 10 Raise the tank cover at the rear and remove it in a forward direction...

Страница 130: ...Position the tank cover Info Note the sealing lip Mount and tighten screw 1 Guideline Screw cover part M5x12 3 5 Nm 2 58 lbf ft 307820 11 Mount and tighten screw 2 Guideline Screw cover part M6 6 Nm 4...

Страница 131: ...Guideline Screw cover part M6 6 Nm 4 4 lbf ft Mount and tighten screw 5 Guideline Screw cover part M5x12 3 5 Nm 2 58 lbf ft Finishing work Install the front side cover p 119 Mount the seat p 107 13 2...

Страница 132: ...13 SERVICE WORK ON THE CHASSIS 130 13 23 Installing the wind shield S00259 11 Position wind shield 1 Mount and tighten screws 2 Guideline Screw wind shield M5 3 5 Nm 2 58 lbf ft...

Страница 133: ...air pressure differ ent brake linings etc the ABS will not function optimally Optimal function ing of the ABS is only ensured if the brake system only contains spare parts and tires that have been app...

Страница 134: ...rates with two independent brake circuits front and rear brakes When the ABS control unit detects a locking tendency in a wheel ABS begins regulating the brake pressure The regulating process causes a...

Страница 135: ...ness of the front and rear brake discs at multiple points on each brake disc to ensure it is at least thickness A Info Wear will reduce the thickness of the brake disc at the contact surface 1 of the...

Страница 136: ...of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help S00269 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal posit...

Страница 137: ...fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil g...

Страница 138: ...ke fluid immediately with water 14 5 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your aut...

Страница 139: ...the rear 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 lini...

Страница 140: ...m 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 out of...

Страница 141: ...es are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Preparatory work Raise the ve...

Страница 142: ...brake discs If the brake linings are not changed in time the steel brake lining carriers grind on the brake disc The braking effect is greatly reduced and the brake discs are destroyed Check the brak...

Страница 143: ...n contact with the ground Remove screw 1 and pull wheel speed sensor 2 out of the hole S00314 10 Remove screws 3 from both brake calipers Press back the brake linings with a light lateral tilting of t...

Страница 144: ...mp Remove screw 4 Warning Danger of accidents Reduced braking efficiency due to damaged brake discs Always lay down the wheel in such a way that the brake discs are not dam aged Holding the front whee...

Страница 145: ...for damage and wear If the wheel bearing is damaged or worn Change the wheel bearing x Clean and grease the shaft seal rings 1 and contact surface A of the spacers Long life grease p 219 S00339 10 In...

Страница 146: ...ront wheel spindle M25x1 5 45 Nm 33 2 lbf ft Thread greased S00314 11 Position the brake calipers and check that the brake linings are seated correctly Mount screws 5 on both brake calipers but do not...

Страница 147: ...ssis screws M6 10 Nm 7 4 lbf ft Remove the vehicle from the center stand p 105 S00315 11 Pull the front brake and compress the fork forcefully a few times The fork legs straighten Tighten screws 8 Gui...

Страница 148: ...10 Main work Press the brake caliper by hand on to the brake disc in order to press back the brake pistons S00277 10 Remove screw 1 and pull wheel speed sensor 2 out of the hole S00276 10 Remove nut...

Страница 149: ...e rear wheel withdraw the wheel spindle Take the rear wheel out of the swing arm Info Do not operate the foot brake when the rear wheel is removed Remove the spacer 7 15 4 Installing the rear wheel x...

Страница 150: ...life grease p 219 Clean and grease the thread of the wheel spindle and nut Long life grease p 219 Mount the rubber dampers and rear sprocket carrier in the rear wheel Place the rear wheel in the swing...

Страница 151: ...eference marks B Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Thread greased S00289 10 Insert wheel speed sensor 6 into the hole Mount and tighten screw 7 Guideline Remaining chassis screws M6 10...

Страница 152: ...d or worn Change all rubber dampers in the rear hub S00291 10 Lay the rear wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub Check the rear sprocket pl...

Страница 153: ...ntrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Warning Danger of acc...

Страница 154: ...ires Info The tire s date of manufacture is usually part of the tire markings and is indi cated by the last four digits of the DOT marking The first two digits refer to the week of manufacture and las...

Страница 155: ...rect the tire pressure Mount the dust cap 15 8 Checking spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that the spoke tension is correct Your authori...

Страница 156: ...e frequency of the sound is a function of the spoke length and spoke diame ter If spokes of the same length and diameter vibrate with a different tone this is an indication that the spoke tensions dif...

Страница 157: ...fo Note the legal regulations regarding the daytime running light 16 2 Removing the battery x Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of t...

Страница 158: ...e engine Remove the seat p 106 S00302 10 Main work Pull locking mechanism 1 in the direction of the arrow Fold open cover 2 S00303 10 Disconnect negative cable 3 of the battery Disconnect the positive...

Страница 159: ...s of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Caution Danger of accidents If the vehicle is operated with a discharged battery or without...

Страница 160: ...rning 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 ac...

Страница 161: ...he battery Rapid recharging with a high charging current shortens the battery s service life If the charging current charging voltage and charging time are exceeded electrolyte escapes through the saf...

Страница 162: ...le s electronics 602678 01 Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 You can also use the battery charger to test the open circuit voltage an...

Страница 163: ...and charging time must not be exceeded Charge the battery regularly when the motorcycle is not in use 3 months 602677 11 Connect both negative cables 3 Guideline Screw battery terminal M6 4 5 Nm 3 32...

Страница 164: ...loaded if the wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Preparatory work Switch off all power consumers and switch off the engine Remove the seat p...

Страница 165: ...consumers of the vehicle Install a new main fuse Fuse 58011109130 p 207 Check that the electrical equipment is functioning properly Mount protection covers Tip Insert a new spare fuse into the starter...

Страница 166: ...e wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Info The fuse box containing the fuses of individual power consumers is located under the seat Preparat...

Страница 167: ...ol units and components Fuse 2 10 A socket ACC1 Fuse 3 25 A ABS hydraulic unit Fuse 4 40 A ABS return pump Fuse 5 not used Use spare fuses with the correct rating only Fuse 58011109110 p 207 Fuse 5801...

Страница 168: ...ff the engine Remove the seat p 106 Remove the front side cover p 118 Remove the tank cover p 126 Remove the mask spoiler x p 120 Remove the wind shield p 129 S00293 10 Main work Remove screws 1 Remov...

Страница 169: ...lighting is functioning properly Position the headlight mask S00293 11 Mount and tighten screws 2 Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft Finishing work Install the wind shield p 130 In...

Страница 170: ...efore mounting Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 106 Remove the front side cover p 118 Remove the tank cover p 126 Remove the mask spoiler x p...

Страница 171: ...headlight p 167 Install the wind shield p 130 Install the mask spoiler x p 123 Install the tank cover p 128 Install the front side cover p 119 Mount the seat p 107 Check the headlight setting p 172 1...

Страница 172: ...Push headlight bulb 1 lightly into the bulb socket turn it all the way counterclock wise and pull it out Disconnect plug 2 S00296 10 Plug connector 2 into the new headlight bulb High beam H11 socket...

Страница 173: ...Clean the lamp and keep it free of grease before mounting B01860 10 Remove the screw on the front of the turn signal housing Carefully remove diffuser 1 Press bulb 2 carefully into the socket turn it...

Страница 174: ...t a distance B under the first mark Guideline Distance B 5 cm 2 in Position the vehicle perpendicular to the wall at a distance A from the wall and switch on the low beam Guideline Distance A 5 m 16 f...

Страница 175: ...wise to increase the headlight range turn counterclockwise to reduce the headlight range If you have a payload you may have to correct the headlight range 400726 11 Set the headlight to marking B Guid...

Страница 176: ...on procedure are invalid but can be reprogrammed in a further activation procedure 401114 10 Loss of a black ignition key additional black ignition keys are available The following procedure deactivat...

Страница 177: ...number of func tional black ignition keys including the orange programming key In this case it flashes twice Switch off the ignition by turning the orange programming key to the OFF position Pull out...

Страница 178: ...e programming key All black ignition keys are deactivated Order a new black ignition key according to the key number on the KEYCODECARD and activate it To activate up to three black ignition keys Pres...

Страница 179: ...nition keys Press the emergency OFF switch to the position ON Insert the orange programming key in the ignition lock Switch on the ignition by turning the orange programming key to the ON position Imm...

Страница 180: ...16 ELECTRICAL SYSTEM 178 Info After the fourth black ignition key has been activated programming is fin ished...

Страница 181: ...ith the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swallowed contact a physician immediately Change c...

Страница 182: ...ater Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immedi atel...

Страница 183: ...26 01 Add coolant until the coolant reaches the specified level Guideline The coolant level must be between MIN and MAX Alternative 1 Coolant p 214 Alternative 2 Coolant mixed ready to use p 214 Mount...

Страница 184: ...menu You can choose from SPORT STREET RAIN and OFFROAD The drive mode selected last is displayed on the right in the segment display Info The drive mode selection has no influence on the ABS 18 2 MTC...

Страница 185: ...18 ENGINE TUNING 183 Info When traction control is active the TC lamp flashes When traction control is switched off the TC lamp is lit...

Страница 186: ...k the engine oil level in the engine oil level viewer Info After switching off the engine wait one minute before checking the level The engine oil level should be in the upper area B of the engine oil...

Страница 187: ...rns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipula...

Страница 188: ...ith the O ring S00335 10 Pull oil filter 4 out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing surface S00336 10 Ins...

Страница 189: ...2 Guideline Remaining engine screws M5 6 Nm 4 4 lbf ft 100773 12 Thoroughly clean magnet A and oil screen B of the oil drain plugs S00333 10 Mount and tighten oil drain plugs 1 with the magnet O ring...

Страница 190: ...prox 3 0 l 3 2 qt Outside temperature 0 C 32 F Engine oil SAE 10W 50 p 215 Outside temperature 0 C 32 F Engine oil SAE 5W 40 p 215 Mount screw plug 5 Danger Danger of poisoning Exhaust gases are toxic...

Страница 191: ...and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight Finishing work Check the engine oil level p 184...

Страница 192: ...the engine oil level viewer Condition Outside temperature 0 C 32 F Engine oil SAE 10W 50 p 215 Condition Outside temperature 0 C 32 F Engine oil SAE 5W 40 p 215 Info In order to achieve optimal engin...

Страница 193: ...sult 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 extra...

Страница 194: ...e fluid etc should be disposed of as stipulated in applicable regulations Info If you clean the motorcycle regularly its value and appearance will be maintained over a long period Avoid direct sunshin...

Страница 195: ...em to evaporate Push back the protection caps of the handlebar controls to allow any water that has penetrated to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings...

Страница 196: ...after riding Warm water would enhance the corrosive effects of salt 401060 01 Clean the motorcycle p 192 Clean the brakes Info After EVERY trip on salted roads thoroughly wash the brake calipers and b...

Страница 197: ...20 CLEANING CARE 195 Clean the chain p 108...

Страница 198: ...ng for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 218 Refuel p 91 Clean the motorcycle p 192 Change the engine oil and filter clean the oil screens x p...

Страница 199: ...the water vapor produced during combustion condenses and causes valves and the exhaust system to rust 21 2 Preparing for use after storage 401059 01 Remove the vehicle from the center stand p 105 Rech...

Страница 200: ...echarge the battery x p 158 Check the quiescent current x Safety start system is faulty Read out the fault memory using the KTM diag nostics tool x ICU is not enabled Activate the ICU x CAN bus commun...

Страница 201: ...up ABS fuse is blown Change the fuses in the fuse box p 164 Wheel speeds of front and rear wheels differ greatly Stop switch off the ignition start again Malfunction in ABS Read out the fault memory...

Страница 202: ...aust 34 mm 1 34 in Valve clearance Exhaust at 20 C 68 F 0 25 0 30 mm 0 0098 0 0118 in Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Crankshaft bearing Sleeve bearing Conrod bearing Sleeve bearing...

Страница 203: ...park plug NGK LMAR7A 9 Electrode gap spark plug 0 8 0 9 mm 0 031 0 035 in Cooling Water cooling permanent circulation of coolant by water pump Cold start device Electric starter 23 2 Engine tightening...

Страница 204: ...2 Nm 8 9 lbf ft Screw coolant connection on cylinder head M6 10 Nm 7 4 lbf ft Screw damping plate M6 10 Nm 7 4 lbf ft Loctite 243 Screw engine case M6x60 10 Nm 7 4 lbf ft Screw engine case M6x80 10 Nm...

Страница 205: ...Step 2 18 Nm 13 3 lbf ft Screw camshaft bearing support M8 10 9 Step 1 8 5 Nm 6 27 lbf ft Step 2 14 5 Nm 10 7 lbf ft Only applies when using Hex key bit 61229025000 Screw engine case M8 18 Nm 13 3 lb...

Страница 206: ...Nm 22 1 lbf ft Step 3 90 Step 4 90 Lubricated with engine oil Coolant temperature sensor M12x1 5 12 Nm 8 9 lbf ft Rotor screw M12x1 5 90 Nm 66 4 lbf ft Spark plug M12x1 5 15 Nm 11 1 lbf ft Nut of engi...

Страница 207: ...0 l 2 54 qt Coolant p 214 Coolant mixed ready to use p 214 23 3 3 Fuel Total fuel tank capacity approx 23 l 6 1 US gal Super unleaded ROZ 95 RON 95 PON 91 p 216 Fuel reserve approx 3 5 l 3 7 qt 23 4 C...

Страница 208: ...4 5 mm 0 177 in Tire air pressure solo with passenger full payload Front with cold tires 2 4 bar 35 psi Rear with cold tires 2 9 bar 42 psi Secondary drive ratio 17 42 Chain 5 8 x 5 16 525 X ring Stee...

Страница 209: ...Fuse 58011109110 10 A Fuse 58011109125 25 A Fuse 58011109130 30 A Fuse 58011109140 40 A Low beam H11 socket PGJ19 2 12 V 55 W High beam H11 socket PGJ19 2 12 V 55 W Parking light LED Instrument light...

Страница 210: ...vailable in the Service section under http www ktm com 23 7 Fork Fork part number 14 18 8N 25 Fork WP Suspension 4860 MXTA SPLIT Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks...

Страница 211: ...per fork leg 720 ml 24 34 fl oz Fork oil SAE 4 48601166S1 p 216 23 8 Shock absorber Shock absorber part number 15 18 7N 25 Shock absorber WP Suspension 4618 BAVP DCC PA Compression damping low speed...

Страница 212: ...5 psi Riding sag 55 mm 2 17 in Static sag 25 mm 0 98 in Fitted length 406 mm 15 98 in Shock absorber oil p 216 SAE 2 5 23 9 Chassis tightening torques Screw combination switch left M4 2 Nm 1 5 lbf ft...

Страница 213: ...m 4 4 lbf ft Nut ABS unit fixation M6 8 Nm 5 9 lbf ft Remaining chassis nuts M6 10 Nm 7 4 lbf ft Remaining chassis screws M6 10 Nm 7 4 lbf ft Screw battery terminal M6 4 5 Nm 3 32 lbf ft Screw brake l...

Страница 214: ...ning chassis screws M8 25 Nm 18 4 lbf ft Screw bottom triple clamp M8 12 Nm 8 9 lbf ft Screw foot brake lever M8 25 Nm 18 4 lbf ft Loctite 243 Screw fork stub M8 15 Nm 11 1 lbf ft Screw front footrest...

Страница 215: ...M10x1 12 Nm 8 9 lbf ft Loctite 243 Screw subframe M10x1 25 45 Nm 33 2 lbf ft Lambda sensor M12x1 25 25 Nm 18 4 lbf ft Screw bottom shock absorber M14x1 5 80 Nm 59 lbf ft Thread greased Screw top shock...

Страница 216: ...astrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant even in countries with high temperatures Using inferior antifreeze can result in corrosi...

Страница 217: ...that possess the corresponding properties Fully synthetic engine oil Recommended supplier Motorex Power Synt 4T Engine oil SAE 5W 40 Standard classification JASO T903 MA p 220 SAE p 220 SAE 5W 40 Gui...

Страница 218: ...draulic oil that complies with the specified standard see specifications on the container and that possesses the corre sponding properties Recommended supplier Motorex Hydraulic Fluid 75 Shock absorbe...

Страница 219: ...aded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or...

Страница 220: ...road use Guideline Recommended supplier Motorex Chainlube Road Cleaning and preserving materials for metal rubber and plastic Recommended supplier Motorex Moto Protect Fuel additive Recommended suppl...

Страница 221: ...ke Grease 2000 Motorcycle cleaner Recommended supplier Motorex Moto Clean Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces Recommended supplier Motorex Quick...

Страница 222: ...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...

Страница 223: ...nings front brake checking 136 rear brake checking 140 Brake system 131 140 Brakes 87 Brakes applying 87 C Capacity coolant 205 engine oil 188 205 fuel 92 205 Center stand 47 Chain checking 112 checki...

Страница 224: ...Temp 62 TPMS 55 Trip 1 54 Trip 2 54 Volume 63 Warnings 57 Combination switch 33 Overview 33 Coolant level compensating tank checking 179 compensating tank correcting 180 Customer service 23 E Electri...

Страница 225: ...usting 70 Handlebar position 67 adjusting 67 Hazard warning flasher 34 Hazard warning flasher switch 34 Headlight daytime running light 155 headlight range adjusting 173 Headlight mask with headlight...

Страница 226: ...for use advice on first use 77 after storage 197 checks and maintenance measures when preparing for use 81 Protective clothing 20 R Rear hub rubber dampers checking 149 Rear sprocket checking 112 Rear...

Страница 227: ...ring head bearing play checking 116 Steering lock 37 Stopping 89 Storage 196 Storage compartment Closing 42 Opening 42 Suspension setting 97 104 Switch on the left side of the handlebar 33 on the righ...

Страница 228: ...el 28 U Use definition 9 V Vehicle loading 79 raising with the center stand 105 removing from the center stand 105 View of vehicle front left 24 rear right side 26 W Warranty 22 Wind shield adjusting...

Страница 229: ...3213108en 3213108en 10 2013 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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