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SERVICE WORK ON THE CHASSIS 12

103

12.1

Raising the motorcycle with rear lifting gear

Note

Danger of damage

The parked vehicle can roll away or fall over.

–

Park the vehicle on a firm and level surface.

402346-01

–

Mount the supports of the lifting gear.

–

Insert the adapter in the rear lifting gear.

Retaining adapter (61029955244)
Rear wheel work stand (69329955000)

–

Stand the motorcycle upright, align the lifting gear to the link
fork and the adapters, and raise the motorcycle.

12.2

Removing the rear of the motorcycle from the lifting gear

Note

Danger of damage

The parked vehicle can roll away or fall over.

–

Park the vehicle on a firm and level surface.

Содержание F4175T2

Страница 1: ...OWNER S MANUAL 2020 200 Duke Art no 3214156en ...

Страница 2: ......

Страница 3: ...he time of going to print However minor differences due to further developments in design cannot be ruled out completely All specifications contained herein are non binding KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical specifications prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt the...

Страница 4: ...permission of the copyright owner ISO 9001 12 100 6061 KTM applies quality assurance processes that lead to the highest possible product quality as defined in the ISO 9001 international quality management standard Issued by TÜV Management Service KTM Sportmotorcycle GmbH Stallhofnerstraße 3 5230 Mattighofen Austria This document is valid for the following models 200 Duke US F4175T2 F4175T3 ...

Страница 5: ...3 Protective clothing 20 2 14 Work rules 21 2 15 Environment 21 2 16 Owner s Manual 22 3 IMPORTANT NOTES 23 3 1 Manufacturer and implied warranty 23 3 2 Fuel auxiliary substances 23 3 3 Spare parts accessories 23 3 4 Service 24 3 5 Figures 24 3 6 Customer service 24 4 VIEW OF VEHICLE 26 4 1 View of vehicle front left example 26 4 2 View of vehicle rear right example 28 5 SERIAL NUMBERS 30 5 1 Vehi...

Страница 6: ...icator 58 7 9 Function buttons 59 7 10 TRIP F display 60 7 11 ODO display 61 7 12 TRIP 1 display 62 7 13 TRIP 2 display 63 7 14 riding time average speed menu 64 7 15 average speed average fuel consumption 1 menu 64 7 16 average fuel consumption 1 average fuel consumption 2 menu 65 7 17 average fuel consumption 2 service menu 66 7 18 service range menu 67 7 19 range riding time menu 68 7 20 Settin...

Страница 7: ...cle off the front lifting gear 106 12 5 Cleaning the dust boots of the fork legs 107 12 6 Removing the passenger seat 109 12 7 Mounting the passenger seat 110 12 8 Removing the front rider s seat 110 12 9 Mounting the front rider s seat 111 12 10 Checking for chain dirt accumulation 112 12 11 Cleaning the chain 112 12 12 Checking the chain tension 114 12 13 Adjusting the chain tension 115 12 14 Ch...

Страница 8: ...arging the 12 V battery 156 15 4 Changing the ABS fuses 159 15 5 Changing the fuses of individual power consumers 162 15 6 Changing the headlight bulb 165 15 7 Checking the headlight setting 168 15 8 Adjusting the headlight range 169 15 9 Changing the turn signal bulb 169 15 10 Diagnostics connector 171 15 11 Front ACC1 and ACC2 171 16 COOLING SYSTEM 172 16 1 Cooling system 172 16 2 Checking the c...

Страница 9: ...SHOOTING 206 22 TECHNICAL DATA 209 22 1 Engine 209 22 2 Engine tightening torques 210 22 3 Capacities 214 22 3 1 Engine oil 214 22 3 2 Coolant 214 22 3 3 Fuel 214 22 4 Chassis 215 22 5 Electrical system 216 22 6 Tires 217 22 7 Fork 217 22 8 Shock absorber 218 22 9 Chassis tightening torques 218 23 SUBSTANCES 225 24 AUXILIARY SUBSTANCES 228 25 STANDARDS 230 26 INDEX OF SPECIAL TERMS 231 27 LIST OF ...

Страница 10: ...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 Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or...

Страница 11: ... rework 1 2 Formats used The typographical formats used in this document are explained below Proprietary name Indicates a proprietary name Name Indicates a protected name Brand Indicates a brand available on the open market Underlined terms Refer to technical details of the vehicle or indicate technical terms which are explained in the glossary ...

Страница 12: ...n arise for people property and the environment through use not as intended Any use of the vehicle beyond the intended and defined use constitutes misuse Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respective use 2 3 Safety advice A number of safety instructions need to be followed to operate the product described safely There...

Страница 13: ...invariably lead to fatal or serious permanent injury if the appropriate measures are not taken Warning Identifies a danger that 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 Identifies a danger that will lead to considerable machine and material damage...

Страница 14: ...2 SAFETY ADVICE 12 2 5 Overview of labels S04248 10 ...

Страница 15: ...SAFETY ADVICE 2 13 1 Type label for Canada 2 Information on emissions control 3 Information on preparations for use 4 Type label for USA 5 Information on noise emissions S04195 01 Type label for Canada ...

Страница 16: ...2 SAFETY ADVICE 14 S04196 01 Information on emissions control F00491 01 Information on preparations for use ...

Страница 17: ...SAFETY ADVICE 2 15 S04198 01 Type label for USA S04197 01 Information on noise emissions ...

Страница 18: ... warranty for the exhaust monitoring system KTM North America Inc guarantees that at the time of sale the exhaust monitoring system complies with all the standards of the US Environmental Protection Agency EPA and the California Air Resources Board CARB This manufacturer warranty applies in respect of the first owner of the motorcycle and all subsequent owners Your exhaust monitoring system may in...

Страница 19: ...facturer warranty for the exhaust monitoring system please address these to KTM North America Inc Customer Support 1119 Milan Ave Amherst OH 44001 USA Phone 888 985 6090 U S Environmental Protection Agency 2000 Traverwood Drive Ann Arbor MI 48105 USA California Air Resources Board 1001 I Street Sacramento CA 95814 USA 2 9 Noise emission warranty KTM warrants that this exhaust system at the time of...

Страница 20: ...line 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 Building Washington DC 20590 You can also obtain other information about motor vehicle safety from the Hotline 2 11 Tampering warning Tampering with the noise control system is prohibited Federal law prohibits the following acts or the causing thereof 1 The removal ...

Страница 21: ...acturer 2 12 Safe operation Danger Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others Do not operate the vehicle if you are not fit to ride due to alcohol drugs or medication Do not operate the vehicle if you are physically or mentally impaired Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Al...

Страница 22: ...er An appropriate driver s license is needed to ride the vehicle on public roads Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop Adhere to the information and warning labels on the vehicle 2 13 Protective clothing Warning Risk of injury Missing or poor protective clothing presents an increased safety risk Wear appropriate protective clothing such as helmet bo...

Страница 23: ...dy been applied to a new part do not apply any additional thread locker After disassembly clean the parts that are to be reused and check them for damage and wear Change damaged or worn parts After completing a repair or service work check the operating safety of the vehicle 2 15 Environment If you use your motorcycle responsibly you can ensure that problems and conflicts do not occur To protect t...

Страница 24: ...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 needed If you would like to know more about the vehicle or have questions on the material you read please contact an authorized KTM dealer The Owner s Manual is an important component of the vehicle and must be handed over to the new owner if the vehicle is sold The Owner...

Страница 25: ...ot allow fuel to enter the groundwater the soil or the sewage system Use fuels and auxiliary substances in accordance with the Owner s Manual and specification 3 3 Spare parts accessories For your own safety only use spare parts and accessory products that are approved and or recommended by KTM and have them installed by an authorized KTM workshop KTM accepts no liability for other products and an...

Страница 26: ...rts before the next sched uled 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 longer service life for your motorcycle The relevant mileage or time interval is whichever occurs first 3 5 Figures The figures contained in the manual may depict special equipment In the interest of clarity some components...

Страница 27: ...IMPORTANT NOTES 3 25 ...

Страница 28: ...4 VIEW OF VEHICLE 26 4 1 View of vehicle front left example S04246 10 ...

Страница 29: ...VIEW OF VEHICLE 4 27 1 Combination instrument 2 Clutch lever p 32 3 Front rider s seat 4 Passenger seat 5 Grab handles p 42 6 Seat lock p 41 7 Side stand p 44 8 Shift lever p 43 ...

Страница 30: ...4 VIEW OF VEHICLE 28 4 2 View of vehicle rear right example S04245 10 ...

Страница 31: ...Light switch p 34 2 Turn signal switch p 35 2 Horn button p 33 3 Ignition and steering lock p 36 4 Emergency OFF switch p 35 4 Start button p 36 5 Throttle grip p 33 6 Hand brake lever p 32 7 Foot brake lever p 44 8 Passenger foot pegs p 42 ...

Страница 32: ...1 Vehicle identification number 402408 10 The vehicle identification number 1 is stamped on the right side of the steering head 5 2 Type label 402174 10 The type label 1 is on the right of the frame behind the steering head ...

Страница 33: ...e sprocket 5 4 Key number 402245 10 The key number 1 can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place If at least one ignition key is still available a spare key can be produced If an ignition key is no longer present the entire lock system must be replaced ...

Страница 34: ...er S00656 10 The clutch lever 1 is fitted on the left side of the handlebar 6 2 Hand brake lever S00663 10 The hand brake lever 1 is fitted on the right side of the handle bar The front brake is engaged using the hand brake lever ...

Страница 35: ...grip 1 is fitted on the right side of the handlebar 6 4 Horn button S00660 10 Horn button 1 is fitted on the left side of the handlebar Possible states The horn button is in the basic position The horn button is pressed The horn is operated in this position ...

Страница 36: ...tail light are switched on High beam on The light switch is turned upwards In this position the high beam and the tail light are switched on 6 6 High beam flasher button S00659 10 High beam flasher button 1 is fitted on the left side of the han dlebar Possible states High beam flasher button in the basic position High beam flasher button pressed In this position the headlight flasher high beam is ...

Страница 37: ...sition after use Right turn signal on Turn signal switch pressed to the right The turn signal switch returns automatically to the central position after use 6 8 Emergency OFF switch S00661 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 igni tion circuit is interrupted a running engine stops and a non running ...

Страница 38: ...ter motor is actuated 6 10 Ignition and steering lock A00632 10 The ignition and steering lock is located in front of the upper triple clamp Possible states Ignition off OFF In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start The ignition key can be removed Ignition on ON In this position the ignition circuit is closed and the engine ...

Страница 39: ...ocking the steering Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 400732 01 Park the vehicle Turn the handlebar all the way to the left Insert the ignition key into the ignition and steering lock press in and turn to the left Remove the ignition key Steering is no longer possible ...

Страница 40: ...ng fuel tank filler cap Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not fuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specificatio...

Страница 41: ...se of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system K00724 10 Lift cover 1 of the fuel tank filler cap and insert the ignition key into the lock Note Danger of damage The ignition key may break...

Страница 42: ...ble toxic and a health hazard Check that the fuel tank filler cap is locked cor rectly after closing Change your clothing if fuel spills on them Rinse the affected area immediately with plenty of water in the event of contact with the skin Close the fuel tank filler cap Push down the fuel tank filler cap until the lock engages ...

Страница 43: ... 6 41 6 15 Seat lock H01991 10 The seat lock 1 is located to the left of the seat The seat lock can be unlocked using the ignition key 6 16 Tool set B00758 10 The tool set 1 is located under the passenger seat ...

Страница 44: ...u carry a passenger the passenger can hold onto the grab handles during the trip 6 18 Passenger foot pegs A00633 10 The passenger foot pegs can be folded up and down Possible states Passenger foot pegs folded up For operation without a pas senger Passenger foot pegs folded down For operation with a pas senger ...

Страница 45: ... 43 6 19 Shift lever 401950 10 Shift lever 1 is mounted on the left side of the engine 401950 11 The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears ...

Страница 46: ...2029 10 The side stand 1 is located on the left of the vehicle The side stand is used for parking the motorcycle Info The side stand must be folded up during motorcycle use The side stand is coupled with the safety starting system follow the riding instructions Possible states Side stand folded out The vehicle can be supported on the side stand The safety starting system is active ...

Страница 47: ...CONTROLS 6 45 Side stand folded in This position is mandatory when riding the motorcycle The safety starting system is inactive ...

Страница 48: ...7 COMBINATION INSTRUMENT 46 7 1 Combination instrument E01184 10 The combination instrument is attached in front of the handlebar 1 Indicator lamps p 52 2 Display p 56 3 Function buttons p 59 ...

Страница 49: ...r indicator lamp The segments of the tachometer and the gear display light up and switch off in sequence The speedometer counts from 0 to 199 and back The remaining display segments of the display light up briefly The READY TO RACE logo appears on the display The display then changes to the last selected mode Info The malfunction indicator lamp always lights up as long as the engine is not running...

Страница 50: ... as an error occurs the relevant indicator lamps light up to signal that an indication warning note for the operating safety has been detected As soon as a warning for operating safety has been detected the general warning lamp also flashes F01476 01 If an error has occurred in the CAN bus various warnings appear on the display CAN FAILURE and CAN EMS FAILURE can occur ...

Страница 51: ... the side stand is folded down Clutch Switch Failure appears on the display if the clutch switch is faulty F01477 01 Transport Lock appears on the display if transport mode is acti vated Not Legal appears on the display if the approval for road use is invalidated by modifications ...

Страница 52: ...n the display if the battery voltage falls below the specified value Battery voltage 10 5 V F01477 04 Coolant Sensor Failure appears on the display if the coolant temper ature sensor is faulty High Coolant Temperature appears on the display if the coolant tem perature rises above the specified value Coolant temperature 110 C 230 F ...

Страница 53: ...MBINATION INSTRUMENT 7 51 F01477 05 Fuel Level Sensor Failure appears on the display if the fuel level indicator is faulty Low Fuel Level appears on the display if the fuel level reaches the reserve mark ...

Страница 54: ... also flashes Info The malfunction indicator lamp always lights up as long as the engine is not running If the engine is running and the malfunction indicator lamp lights up stop taking care not to endanger yourself or other road users in the process and contact an authorized KTM workshop Possible states The turn signal indicator lamp flashes green simul taneously with the turn signal The turn sig...

Страница 55: ...dle indicator lamp lights up green The trans mission is in neutral The high beam indicator lamp lights up blue The high beam is switched on The immobilizer indicator lamp lights up red Status or error message for immobilizer The general warning lamp flashes yellow A note warning note on operating safety has been detected This is also shown in the display ABS warning lamp lights up yellow Status or...

Страница 56: ...s always active during the running in phase up to 1 000 km 621 mi The shift warning light can only be deactivated and the values for RPM1 and RPM2 can only be adjusted after this The shift warning light flashes red at RPM1 and the shift warning light lights up red at RPM2 Info In sixth gear the shift warning light is deactivated when the engine is warm after the first service Coolant temperature 3...

Страница 57: ...COMBINATION INSTRUMENT 7 55 Coolant temperature 35 C 95 F ODO 1 000 km 620 mi RPM1 shift warning light flashes RPM2 shift warning light lights up ...

Страница 58: ... or in miles per hour mph The fuel level display is displayed in the 4 area The display 5 shows additional information The time appears in area 6 The coolant temperature display appears in area 7 Info The time must be reset if the 12 V battery was discon nected from the vehicle or the fuse was removed The brightness of the displays is controlled by an ambient light sensor in the combination instru...

Страница 59: ...appear on the display The fuel level is displayed with a slight delay to prevent the indicator from constantly moving while riding The fuel level display is not updated while the side stand is folded out or the emergency off switch is switched off Once the side stand is folded up and the emergency OFF switch is switched on the fuel level display is next updated after 2 minutes The fuel level displ...

Страница 60: ...ng is displayed stop imme diately and take care not to endanger yourself or other traffic participants in the process Allow the engine and cooling system to cool down Check and if necessary correct the coolant level on the cool ing system while it is in a cooled state Info When all the bars light up the warning High Coolant Tem perature appears on the display If the cooling system overheats the ma...

Страница 61: ...s light up 7 9 Function buttons F01464 10 Press the MODE button 1 to change display modes Possible display modes are TRIP F after reaching the fuel reserve level total distance traveled ODO distance 1 TRIP 1 distance 2 TRIP 2 and ABS mode ABS Press the SET button 2 to change menus Button 3 has no function ...

Страница 62: ...ppears on the display Pressing the MODE button briefly changes the display mode to TRIP F and starts to count from 0 0 regardless of the previously active display mode In the TRIP F display the menus Fuel Range and Actual F C can also be displayed As soon as a warning for operating safety has been detected the general warning lamp also flashes Press the SET button briefly to change to the next men...

Страница 63: ...edly until ODO appears on the display ODO shows the total distance covered Info This value is retained even if the 12 V battery is discon nected from the vehicle or the fuse blows Press the SET button briefly Next menu on the display Press the MODE button briefly Next display mode in the display ...

Страница 64: ...on the display TRIP 1 shows the distance since the last reset such as between two refueling stops TRIP 1 is always running and counts up to 9999 9 Press the SET button briefly Next menu on the display Press the SET button for 3 seconds Display of TRIP 1 is reset Press the MODE button briefly Next display mode on the display ...

Страница 65: ...on the display TRIP 2 shows the distance since the last reset such as between two refueling stops TRIP 2 is always running and counts up to 9999 9 Press the SET button briefly Next menu on the display Press the SET button for 3 seconds Display of TRIP 2 is reset Press the MODE button briefly Next display mode on the display ...

Страница 66: ... menu on the display Press the MODE button briefly Next display mode on the display 7 15 average speed average fuel consumption 1 menu F01472 02 Press the SET button briefly and repeatedly until the desired menu appears In this menu the average speed and the average fuel consumption 1 are displayed in L 100 km or L 100 miles Info The average fuel consumption 1 is displayed after several 100 meters...

Страница 67: ...enu F01472 03 Press the SET button briefly and repeatedly until the desired menu appears In this menu the average fuel consumption 1 in L 100 km or L 100 miles and the average fuel consumption 2 in km L or miles L are displayed Info The average fuel consumptions 1 and 2 are displayed after several 100 meters of travel after the ignition is switched on Press the SET button briefly Next menu on the ...

Страница 68: ...tedly until the desired menu 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 average fuel consumption 2 is displayed after several 100 meters of travel after the ignition is switched on Press the SET button briefly Next menu on the display Press the MODE button briefly Next display mode on the display ...

Страница 69: ...ws 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 displayed after several 100 meters of travel after the ignition is switched on Press the SET button briefly Next menu on the display Press the MODE button briefly Next display mode on the display ...

Страница 70: ...verage fuel consumption and the fuel quantity in the fuel tank The range is displayed after several 100 meters of travel after the ignition is switched on Press the SET button briefly Next menu on the display Press the MODE button briefly Next display mode on the display 7 20 Setting the kilometers or miles Info Make the setting according to the country If you change the unit the value ODO is reta...

Страница 71: ...473 01 Press the MODE button briefly and repeatedly until ODO appears on the display Press the MODE button for 5 seconds The display changes from km h to mph or from mph to km h Info The units can be set on the ODO display for each menu by keeping the MODE button pressed ...

Страница 72: ... the MODE button briefly and repeatedly until ODO appears on the display Press the MODE and SET buttons for 5 10 seconds The time display begins to flash Info The clock can be set in the ODO display for each menu by keeping the MODE button and SET button pressed simultaneously Set the hours display using the MODE button Set the minutes display using the SET button Press the MODE button and SET but...

Страница 73: ...play appears in the TRIP 1 display for each menu by keeping the MODE button pressed RPM1 is the engine speed above which the shift warn ing light starts flashing The engine speed can be set at intervals of 50 The shift speed RPM1 can only be set up to maximum 50 revolutions per minute below the shift speed RPM2 Adjust the speed with the MODE button and SET button Info The MODE button increases the...

Страница 74: ... 2 appears on the display Press the MODE button for 5 seconds The RPM2 display appears Info The RPM2 display appears in the TRIP 2 display for each menu by keeping the MODE button pressed RPM2 is the engine speed above which the shift warn ing light lights up The engine speed can be set at intervals of 50 The shift speed RPM2 can only be set from a minimum of 50 revolutions per minute above the sh...

Страница 75: ...taneously The RPM2 display disappears and the set shift speed RPM2 is adopted and saved 7 24 Adjusting ABS mode Condition The motorcycle is stationary S04227 01 Press the Mode button briefly and repeatedly until the ABS display appears SET Press and hold the button until Release Button is dis played The now active ABS mode is shown in the display ...

Страница 76: ... mode will remain active A flashing ABS mode indicates that the ABS mode dis played does not match the actual ABS mode due to a malfunction If ABS mode ROAD is enabled ABS controls both wheels If the ABS mode SUPERMOTO is enabled ABS only con trols the front wheel The rear wheel is not controlled by ABS and may lock during braking maneuvers ...

Страница 77: ...met boots gloves as well as trousers and a jacket with protectors on all rides Always wear protective clothing that is in good condition and meets the legal regulations Warning Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling charac teristic Different tire tread patterns can make the vehicle significantly more difficult to control Make sure that only...

Страница 78: ...e sales inspection work has been carried out by an authorized KTM workshop The delivery certificate is transferred upon vehicle handover Read the entire Owner s Manual before riding for the first time Get to know the controls Get used to the handling characteristic of the motorcycle on suitable terrain before undertaking a more chal lenging ride Also ride as slowly as possible to get a better feel...

Страница 79: ... warning light is set to a specified value and cannot be changed Avoid fully opening the throttle 8 3 Loading the vehicle Warning Danger of accidents Total weight and axle loads influence the handling characteristic The total weight consists of motorcycle ready for operation and with a full tank driver and passenger with protective clothing and helmet and luggage Do not exceed the maximum permissi...

Страница 80: ...en mounting cases Warning Danger of accidents Luggage which has slipped impairs visibility If the tail light is covered you are less visible to traffic behind you especially when it is dark Check that your luggage is fixed properly at regular intervals Warning Danger of accidents A high payload alters the handling characteristic and increases the stopping distance Adapt your speed to your payload ...

Страница 81: ...e vehicle and ensure even weight distribution between the front and rear wheels Do not exceed maximum permissible weight and maximum permissible axle loads Guideline Maximum permissible overall weight 335 kg 739 lb Maximum permissible front axle load 125 kg 276 lb Maximum permissible rear axle load 210 kg 463 lb ...

Страница 82: ...ke fluid level p 131 Check the front brake linings p 130 Check the rear brake linings p 135 Check that the brake system is functioning properly Check the coolant level p 174 Check for chain dirt accumulation p 112 Check the chain tension p 114 Check the tire condition p 150 Check tire pressure p 152 Check the settings of all controls and ensure that they can be operated smoothly Check that the ele...

Страница 83: ... Electronic components and safety devices will be damaged if the 12 V battery is dis charged or missing Never operate the vehicle with a discharged 12 V battery or without a 12 V battery Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine Dust and dirt will enter the engine without an air filter Never start to use the vehicle without an air filter Note ...

Страница 84: ...osition Switch on the ignition by turning the ignition key to the posi tion After you switch on the ignition you can hear the fuel pump working for about two seconds The function check of the combination instrument is run at the same time Shift the transmission into neutral Green idle indicator lamp N lights up The ABS warning lamp lights up and goes back out after starting off Press start button ...

Страница 85: ...tem You can only start the engine if the transmission is in neutral or if the clutch lever is pulled when a gear is engaged If the side stand is folded out and you shift into gear and release the clutch lever the engine stops 9 3 Starting off Pull the clutch lever engage 1st gear release the clutch lever slowly and simultaneously open the throttle carefully Tip If the engine dies while starting of...

Страница 86: ...g Danger of accidents If you change down at high engine speed the rear wheel blocks and the engine races Do not change into a low gear at high engine speed Warning Danger of accidents An incorrect ignition key position causes malfunctions Do not change the ignition key position while driving Warning Danger of accidents Adjustments to the vehicle distract attention from traffic activity Make all ad...

Страница 87: ...ning Danger of accidents A risky riding style constitutes a major risk Comply with traffic regulations and ride defensively and with foresight to detect sources of danger as early as possible Warning Danger of accidents Cold tires have reduced road grip Ride the first miles carefully on every journey at moderate speed until the tires reach operating tem perature Warning Danger of accidents New tir...

Страница 88: ... use Note Engine failure Overheating damages the engine If the coolant temperature warning is displayed stop immediately and take care not to endanger yourself or other traffic participants in the process Allow the engine and cooling system to cool down Check and if necessary correct the coolant level on the cooling system while it is in a cooled state Info If unusual noises occur while riding sto...

Страница 89: ...ting temperature is reached when 4 bars of the temperature indicator light up Only open the throttle as much as the engine can handle abrupt throttle grip opening increases fuel consumption Accelerate only up to a speed suitable for the road surface and weather conditions Particularly in bends do not shift and accelerate very carefully Brake if necessary and close the throttle at the same time in ...

Страница 90: ...y several times to dry out and remove dirt from the brake linings and the brake discs Warning Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency Check the brake system and do not continue riding until the problem is eliminated Your authorized KTM workshop will be glad to help Warning Danger of accidents The brake system fails in the event of overheati...

Страница 91: ...pping distance in certain situations Adjust application of the brakes to the respective riding situation and riding surface conditions Warning Danger of accidents Excessively forceful application of the brakes blocks the wheels The ABS effectiveness is only ensured if it is switched on Leave the ABS switched on in order to benefit from the protective effect When braking release the throttle and ap...

Страница 92: ...er gear appropriate to your speed Use the braking effect of the engine on long downhill stretches Shift back one or two gears but do not over rev the engine when doing so This means that significantly less braking is required and the brake system does not overheat 9 6 Stopping parking Warning Risk of injury People who act without authorization endanger themselves and others Do not leave the vehicl...

Страница 93: ...icant damage may be caused if the vehicle rolls away or falls over The components for parking the vehicle are designed only for the weight of the vehicle Park the vehicle on a firm and level surface Ensure that nobody sits on the vehicle when the vehicle is parked on a stand Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk Do not park the vehicle near to materials whic...

Страница 94: ...itch is intended for emergencies 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 37 9 7 Transport Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk Do n...

Страница 95: ...eling Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not fuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling ...

Страница 96: ... the eyes Change your clothing in case of fuel spills on them Note Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged In some countries and regions the available fuel quality and cleanliness may not be sufficient This will result in problems with the fuel system Refuel only with clean fuel that meets the specified standards Your authorized KTM workshop will be...

Страница 97: ...ff the engine Open the fuel tank filler cap p 38 Fill the fuel tank with fuel up to the lower edge 1 of the fuel filler Total fuel tank capacity approx 11 l 2 9 US gal Super unleaded ROZ 95 RON 95 PON 91 p 227 Close the fuel tank filler cap p 40 ...

Страница 98: ...e service schedule can always be found on KTM Dealer net Your authorized KTM dealer will be happy to advise you 10 2 Required work every 24 months every 12 months every 15 000 km 9 300 mi every 7 500 km 4 650 mi after 1 000 km 620 mi Read out the fault memory using the KTM diagnostics tool Check that the electrical system is functioning properly Change the engine oil and oil filter clean the oil s...

Страница 99: ...heck the chain rear sprocket and engine sprocket p 117 Check the chain tension p 114 Check the coolant level p 174 Check that the radiator fan is functioning properly Change the air filter clean the air filter box Check that the throttle cables are undamaged routed without sharp bends and set cor rectly Check the cables for damage and routing without sharp bends Check the valve clearance change th...

Страница 100: ...cle is roadworthy and take a test ride Read out the error memory after the test ride using the KTM diagnostics tool Reset the service interval display Make a service entry in KTM Dealer net One time interval Periodic interval 10 3 Recommended work every 48 months every 12 months every 30 000 km 18 600 mi every 7 500 km 4 650 mi after 1 000 km 620 mi Check the frame Check the link fork ...

Страница 101: ...lay Check the antifreeze Change the coolant p 183 Empty the drainage hoses Check all hoses e g fuel coolant bleeder drainage etc and sleeves for cracking leaks and incorrect routing Grease all moving parts e g side stand hand lever chain and check for smooth operation Check the tightness of the safety relevant screws and nuts which are easily accessi ble One time interval Periodic interval ...

Страница 102: ...initial status of the 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 lug gage and a passenger thus ensuring an ideal compromise between handling and stability S04220 10 Adjust the spring preload by turning adjusting ring 1 using the hook wrench from the tool set Guideline Spring preload Standard 3 clicks...

Страница 103: ...sen nuts 1 Adjust the shift lever by turning shift rod 2 Guideline Shift rod adjustment range A 110 122 mm 4 33 4 8 in Info Make the same adjustments on both sides At least five screw threads must be screwed into the seating Check adjusting angle B Guideline Adjusting angle B shift rod bell crank shift lever 90 Tighten nuts 1 ...

Страница 104: ...s have been tightened the bearings of the shift rod must be central and aligned identically to each other in order to ensure freedom of movement in the bearing shells Check the shift lever to ensure it is functioning properly and can move freely ...

Страница 105: ...upports of the lifting gear Insert the adapter in the rear lifting gear Retaining adapter 61029955244 Rear wheel work stand 69329955000 Stand the motorcycle upright align the lifting gear to the link fork and the adapters and raise the motorcycle 12 2 Removing the rear of the motorcycle from the lifting gear Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a ...

Страница 106: ...fting gear and lean the vehicle on side stand 1 Remove bushings kit 12 3 Lifting the motorcycle with the front lifting gear Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface Preparatory work Raise the motorcycle with the rear lifting gear p 103 ...

Страница 107: ...emove protection cap 1 402345 01 Move the handlebar to the straight ahead position Position the lifting gear Mounting pin 69329965030 Front wheel work stand large 69329965100 Info Always raise the motorcycle at the rear first Lift the motorcycle at the front ...

Страница 108: ... the motorcycle off the front lifting gear Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 402777 01 Main work Secure the motorcycle against falling over Remove the front lifting gear ...

Страница 109: ...tion cap 1 Finishing work Remove the rear of the motorcycle from the lifting gear p 103 12 5 Cleaning the dust boots of the fork legs Preparatory work Raise the motorcycle with the rear lifting gear p 103 Lift the motorcycle with the front lifting gear p 104 ...

Страница 110: ...is dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when nec essary Clean and oil the dust boots and inner fork tubes of both fork legs Universal oil spray p 229 Press dust boots 2 of both fork legs back into t...

Страница 111: ...ng gear p 106 Remove the rear of the motorcycle from the lifting gear p 103 12 6 Removing the passenger seat H01991 10 Insert the ignition key in seat lock 1 and turn it clockwise Raise the rear of the seat push it towards the rear and lift it off Remove the ignition key from the seat lock ...

Страница 112: ...ward Press the passenger seat downward until it clicks into place Warning Danger of accidents The seat can come loose from the anchoring if it is not mounted correctly After assembly check whether the seat is correctly locked and cannot be pulled up Finally check that the passenger seat is correctly mounted 12 8 Removing the front rider s seat Preparatory work Remove the passenger seat p 109 ...

Страница 113: ...ider s seat pull it towards the rear and remove it upwards 12 9 Mounting the front rider s seat H01994 01 Main work Attach the front rider s seat in area A and lower at the rear Finally check that the front rider s seat is correctly mounted Finishing work Mount the passenger seat p 110 ...

Страница 114: ... chain p 112 12 11 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip Remove lubricants from the tires using a suitable cleaning agent Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary ...

Страница 115: ...ons Info The service life of the chain depends largely on its maintenance Preparatory work Raise the motorcycle with the rear lifting gear p 103 400725 01 Main work Clean the chain regularly Rinse off loose dirt with a soft jet of water Remove old grease remains with chain cleaner Chain cleaner p 228 After drying apply chain spray Street chain spray p 229 Finishing work Remove the rear of the moto...

Страница 116: ... sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Raise the motorcycle with the rear lifting gear p 103 M00714 10 Main work Shift the transmission into neutral In the area after the chain sliding guard press the chain upward toward the link fork ...

Страница 117: ... the chain is tensioned too much the chain engine sprocket rear sprocket transmission and rear wheel bearings wear more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the ...

Страница 118: ...at the markings on the left and right chain adjusters 4 are in the same position relative to the reference marks A The rear wheel is then correctly aligned Info The top chain section must be taut Chain wear is not always even so you should check the setting at different chain positions Tighten nuts 2 Make sure that chain adjusters 4 are fitted correctly on adjusting screws 3 Tighten nut 1 Guidelin...

Страница 119: ... rear sprocket and engine sprocket Preparatory work Raise the motorcycle with the rear lifting gear p 103 100132 10 Main work Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the drivetrain kit Info The engine sprocket rear sprocket and chain should always be replaced together ...

Страница 120: ...he lower chain section Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance B from 20 chain rollers at the longest chain section 301 6 mm 11 874 in If distance B is greater than the specified measurement Change the drivetrain kit Info When a new chain is mounted the rear sprocket and engine sprocket should also be changed New chains...

Страница 121: ...ing guard for wear If screw 1 becomes visible in area C of the chain slid ing guard when viewed from above Change the chain sliding guard Check that the chain sliding guard is firmly seated Finishing work Remove the rear of the motorcycle from the lifting gear p 103 ...

Страница 122: ...0 12 15 Removing the front spoiler S04212 10 Remove screws 1 Take off the front spoiler 12 16 Fitting front spoiler S04212 10 Position the front spoiler Mount and tighten screws 1 Guideline Screw front spoiler rear M6x9 9 Nm 6 6 lbf ft ...

Страница 123: ... 121 12 17 Removing the front fender 307348 10 Remove screws 1 Remove the front fender 12 18 Installing the front fender 307348 10 Position the front fender Mount and tighten screws 1 Guideline Screw front fender M6 7 Nm 5 2 lbf ft ...

Страница 124: ...n with the front brake applied away from public road traffic if the ABS is switched off Do not make any changes to the suspension travel Only use spare parts on the brake system which have been approved and recommended by KTM Only use tires wheels approved by KTM with the corre sponding speed index Maintain specified tire pressure Ensure that service work and repairs are performed professionally Y...

Страница 125: ...ility ABS has two operating modes the Road and SupermotoABS modes In the Road ABS mode the ABS controls both wheels In ABS mode Supermoto the ABS only controls the front wheel The ABS warning lamp 3 flashes slowly to remind you that the Supermoto ABS mode is enabled Info In the Supermoto ABS mode the rear wheel may lock and there is a risk of falling The ABS operates with two independent brake cir...

Страница 126: ...l only ABS control is not available The ABS warning lamp may also light up if the rotating speeds of the front and rear wheels differ greatly under extreme riding con ditions for example when making wheelies or if the rear wheel spins This causes the ABS to switch off To reactivate the ABS stop the vehicle and switch off the ignition The ABS is reactivated when the vehicle is switched on again The...

Страница 127: ...1 of the brake linings Brake discs wear limit front 4 5 mm 0 177 in rear 3 6 mm 0 142 in If the brake disc thickness is less than the specified value Change the front brake disc Change the rear brake disc Check the front and rear brake discs for damage cracking and deformation If the brake disc exhibits damage cracking or deforma tion Change the front brake disc Change the rear brake disc ...

Страница 128: ...g until the problem is eliminated Your authorized KTM workshop will be glad to help Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your authorized KTM workshop will be glad to help C00200 10 Move the brake reservoir mounted on the handlebar into a hori zontal position ...

Страница 129: ...ll be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the s...

Страница 130: ...substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean br...

Страница 131: ...hori zontal position Remove screws 1 Take off cover 2 with membrane 3 Add brake fluid to level A Guideline Dimension A 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 225 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immediately with water ...

Страница 132: ...ing effect If the brake linings are not changed in time the brake lining carriers grind against the brake disc As a consequence the braking effect is greatly reduced and the brake discs are destroyed Check the brake linings regularly B00739 10 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified Change the front brake lini...

Страница 133: ...d do not continue riding until the problem is eliminated Your authorized KTM workshop will be glad to help Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your authorized KTM workshop will be glad to help S04213 10 Position the vehicle upright Check the brake fluid leve...

Страница 134: ...l be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the sk...

Страница 135: ...substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean br...

Страница 136: ...off the screw cap lock S04214 10 Position the vehicle upright Remove screw cap 2 with membrane 3 Add brake fluid up to the marking A Brake fluid DOT 4 DOT 5 1 p 225 Mount the screw cover with the membrane Info Use water to immediately clean up any brake fluid that has overflowed or spilled ...

Страница 137: ... linings reduce the braking effect Ensure that worn out brake linings are replaced immediately Your authorized KTM workshop will be glad to help Warning Danger of accidents Damaged brake discs reduce the braking effect If the brake linings are not changed in time the brake lining carriers grind against the brake disc As a consequence the braking effect is greatly reduced and the brake discs are de...

Страница 138: ...linings for damage and cracking If there is wear or tearing Change the rear brake linings 13 9 Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specif...

Страница 139: ...nd forth between the end stop and the contact to the foot brake cylinder piston and check free travel A Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the free travel of the foot brake lever p 138 Reconnect spring 1 ...

Страница 140: ...ever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification ...

Страница 141: ...Detach spring 1 Release nut 2 and use screw 3 to adjust the specified free travel A Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Info The range of adjustment is limited Hold screw 3 and tighten nut 2 Attach spring 1 ...

Страница 142: ...he side Remove screw 2 and pull wheel speed sensor 3 out of the hole Loosen screw 4 by several rotations Loosen screws 5 Press on screw 4 to push the wheel spindle out of the axle clamp Remove screw 4 Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Hold the front wheel and remove the wheel spindle ...

Страница 143: ...scs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary B01392 10 Main work Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change front wheel bearing Clean and grease shaft seal rings 1 and contact surfaces A of the spacers Long life grease p 228 Insert the spacers ...

Страница 144: ... lbf ft Position wheel speed sensor 3 in the hole Mount and tighten screw 4 Guideline Screw wheel speed sensor holder M6 8 Nm 5 9 lbf ft Mount and tighten screws 5 Operate the hand brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point Take the motorcycle off the front lifting gear p 106 Operate the front brake and compress the fork a few t...

Страница 145: ... Guideline Screw fork stub M8 15 Nm 11 1 lbf ft Finishing work Remove the rear of the motorcycle from the lifting gear p 103 14 3 Removing rear wheel Preparatory work Raise the motorcycle with the rear lifting gear p 103 ...

Страница 146: ...th the washer and chain adjuster 4 Push the rear wheel forward as far as possible and take the chain off the rear sprocket Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Pull the rear wheel back and take it out of the link fork Info Do not operate the foot brake lever when the rear wheel is remove...

Страница 147: ...ith at the rear brake after installing the rear wheel Actuate the foot brake several times before going on a ride until you can feel a firm pressure point Main work Check the rear hub damping rubber pieces p 148 S00675 10 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the rear wheel bearing Clean and grease shaft seal rings 1 and contact surfaces A of th...

Страница 148: ...n the contact areas on the brake caliper bracket and link fork Mount the damping rubber and rear sprocket carrier on the rear wheel Position the rear wheel The brake linings are correctly positioned Push the rear wheel forward as far as possible and lay the chain on the rear sprocket ...

Страница 149: ... in contact with the screws and tighten nut 2 Guideline In order for the rear wheel to be correctly aligned the mark ings on the left and right chain adjusters must be in the same position relative to reference markings B Nut rear wheel spin dle M14x1 5 98 Nm 72 3 lbf ft Position wheel speed sensor 5 in the hole Mount and tighten screw 6 Guideline Screw wheel speed sensor holder M6 8 Nm 5 9 lbf ft...

Страница 150: ...ieces are not changed in time the rear sprocket carrier and the rear hub will be damaged Preparatory work Raise the motorcycle with the rear lifting gear p 103 Remove the rear wheel p 143 S00677 10 Main work Check bearing 1 If the bearing is damaged or worn Change the rear wheel bearing Check damping rubber pieces 2 of the rear hub for damage and wear If the damping rubber pieces of the rear hub a...

Страница 151: ...nd try to rotate the rear sprocket Info Measure the play on the outside of the rear sprocket Play of damping rubber pieces on rear wheel 5 mm 0 2 in If clearance A is larger than the specified value Change all the damping rubber pieces of the rear hub Finishing work Install the rear wheel p 145 Remove the rear of the motorcycle from the lifting gear p 103 Check the chain tension p 114 ...

Страница 152: ...rent tire tread patterns can make the vehicle significantly more difficult to control Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel Warning Danger of accidents Non approved or non recommended tires and wheels impact the handling character istic Only use tires wheels approved by KTM with the corresponding speed index Info The type condition and p...

Страница 153: ...read depth 2 mm 0 08 in If the tread depth is less than the minimum tread depth Change the tires H01144 10 Check the tire age Info The tire date of manufacture is usually contained in the tire label and is indicated by the last four digits of the DOT number The first two digits indicate the week of manufacture and the last two digits the year of manu facture KTM recommends that the tires be change...

Страница 154: ...ure ensures optimal riding comfort and maximum tire service life 400695 01 Remove the protection cap Check the tire pressure when the tires are cold Tire pressure when solo front 2 0 bar 29 psi rear 2 0 bar 29 psi Tire pressure with passenger full payload front 2 0 bar 29 psi rear 2 2 bar 32 psi If the tire pressure does not meet specifications Correct the tire pressure Mount the protection cap ...

Страница 155: ...t with battery acid and battery gases Keep sparks or open flames away from the 12 V battery Only charge 12 V batteries in well ventilated rooms Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and battery gases get into the eyes Preparatory work Remove the pa...

Страница 156: ...onnect positive cable 3 from the 12 V battery Detach rubber strap 4 Pull the 12 V battery upwards and out of the battery compart ment Info Never operate the motorcycle with a discharged 12 V battery or without a 12 V battery In both cases elec trical components and safety devices can be damaged The vehicle will therefore no longer be roadworthy ...

Страница 157: ...e The terminals of the battery must face upwards 12 V battery ETZ 9 BS p 216 Attach rubber strap 1 Position positive cable 2 and mount and tighten the screw Position positive terminal cover 3 V01273 11 Position negative cable 4 and mount and tighten the screw Finishing work Mount the front rider s seat p 111 Mount the passenger seat p 110 ...

Страница 158: ...or open flames away from the 12 V battery Only charge 12 V batteries in well ventilated rooms Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and battery gases get into the eyes Note Environmental hazard 12 V batteries contain environmentally hazardous mater...

Страница 159: ...e escapes through the safety valves This reduces the capacity of the 12 V battery If the 12 V battery is depleted by repeated starting the 12 V battery must be charged immediately If the 12 V battery is left in a discharged state for an extended period it will become deeply discharged and sulfating occurs destroying the battery The 12 V battery is maintenance free The acid level does not have to b...

Страница 160: ...ercharge the 12 V battery using this device Info Never remove cover 1 Charge the 12 V battery to a maximum of 10 of the capacity specified on battery housing 2 Switch off the battery charger after charging and disconnect from the 12 V battery Guideline The charging current charging voltage and charging time must not be exceeded Recharge the 12 V battery regularly when the motorcy cle is not being ...

Страница 161: ...rrect fuses overload the electrical system Only use fuses with the required ampere value Do not bypass or repair fuses Info Two fuses for the ABS are located under the passenger seat These fuses protect the return pump and the hydraulic unit of the ABS The third fuse which protects the ABS control unit is located in the fuse box Preparatory work Remove the passenger seat p 109 ...

Страница 162: ...use has a burned out fuse wire A Warning Fire hazard Incorrect fuses overload the electrical system Only use fuses with the required ampere value Do not bypass or repair fuses Insert the spare fuse with the correct rating Fuse 75011088010 p 216 Tip Insert spare fuse 2 in the fuse box so that it is available if needed Mount the protection cap ...

Страница 163: ...ard Incorrect fuses overload the electrical system Only use fuses with the required ampere value Do not bypass or repair fuses Insert the spare fuse with the correct rating Fuse 75011088015 p 216 Tip Insert spare fuse 4 in the fuse box so that it is available if needed Mount the protection cap Finishing work Mount the passenger seat p 110 ...

Страница 164: ... 15 5 Changing the fuses of individual power consumers Info The fuse box with the main fuse and the fuses of the individual power consumers is located under the pas senger seat Preparatory work Remove the passenger seat p 109 ...

Страница 165: ...e Fuse 2 10 A combination instrument Fuse 3 10 A power relay Fuse 4 15 A ignition coil fuel pump relay starter relay horn Fuse 5 10 A radiator fan Fuse 6 15 A brake light turn signal high beam low beam position light tail light license plate lamp Fuse 7 10 A ABS control unit CAN bus combination instrument Fuse 8 10 A emergency OFF switch Fuse 9 10 A ACC1 Fuse 10 10 A ACC2 ...

Страница 166: ...e required ampere value Do not bypass or repair fuses Insert the spare fuse with the correct rating Fuse 75011088010 p 216 Fuse 75011088015 p 216 Fuse 75011088030 p 216 Tip Put a spare fuse in the fuse box so that it is available if needed Check that the power consumer is functioning properly Close the fuse box cover Finishing work Mount the passenger seat p 110 ...

Страница 167: ... reflector reduces the light intensity Grease on the bulb will evaporate due to the heat and be deposited on the reflector Clean and degrease the bulbs before mounting Do not touch the bulbs with your bare hands S04238 10 Main work Remove screw 1 Lift the headlight mask slightly and swing forward ...

Страница 168: ...connector 3 K00794 10 Detach retaining clamp 4 Remove headlight bulb 5 Position the new headlight bulb in the headlight housing Guideline Insert the headlight bulb so that the holding lugs latch into the recesses Headlight H4 socket P43t p 216 Attach retaining clamp 4 ...

Страница 169: ...t protection cap 2 Swivel the headlight mask upward S04238 10 Mount screw 1 Info Screw 1 also secures the headlight Ensure the screw is always screwed in far enough Check that the lighting is functioning properly Finishing work Check the headlight setting p 168 ...

Страница 170: ...n 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 ft The rider now mounts the motorcycle with luggage and passen ger if applicable Check the headlight setting The light dark boundary must be exactly on the lower mark ing when the motorcycle is ready to be operated with the rider mounted along with any luggage and a passenge...

Страница 171: ...you may have to correct the headlight range Screw 1 also secures the headlight Ensure the screw is always screwed in far enough Finishing work Check the headlight setting p 168 15 9 Changing the turn signal bulb Note Damage to reflector Grease on the reflector reduces the light intensity Grease on the bulb will evaporate due to the heat and be deposited on the reflector Clean and degrease the bulb...

Страница 172: ...ne Do not touch the reflector with your fingers and keep it free from grease Push the new bulb gently into the socket and turn it clockwise all the way in Turn signal RY10W socket BAU15s p 217 Check that the turn signal is functioning properly Position the turn signal glass Guideline Insert holding lug A into cut out B Insert the screw and first turn counterclockwise until it engages in the thread...

Страница 173: ...ostics connector S04236 10 Diagnostics connector 1 is located under the passenger seat 15 11 Front ACC1 and ACC2 S04237 10 Installation location Power supplies ACC1 1 and ACC2 2 front are located behind the left side beneath the fuel tank ...

Страница 174: ...ming of the cooling system is regulated by a valve in radiator cap 2 Heat expansion causes excess coolant to flow into compensating tank 3 When the tem perature falls this surplus coolant is sucked back into the cooling system This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions 110 C 230 F ...

Страница 175: ...led by the air stream and a radiator fan 4 which is activated at high temperature The lower the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect Info If the cooling system overheats the maximum engine speed is limited ...

Страница 176: ...ents of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of wat...

Страница 177: ...ied value Correct the coolant level Coolant p 225 K00742 10 Remove the radiator cap 2 and check the coolant level in the radiator The radiator must be completely filled If the coolant level does not match the specified value Correct the coolant level and find out the cause of the loss Coolant p 225 If you had to add more coolant than the specified amount 0 20 l 0 21 qt Fill bleed the cooling syste...

Страница 178: ...r components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plent...

Страница 179: ...reeze 25 45 C 13 49 F If the antifreeze in the coolant does not match the speci fied value Correct the coolant antifreeze Check the coolant level in the compensating tank The coolant level must be between MIN and MAX If the coolant level does not match the specified value Correct the coolant level Coolant p 225 Mount the cap of the compensating tank ...

Страница 180: ...orrect the coolant antifreeze Check the coolant level in the radiator The radiator must be completely filled If the coolant level does not match the specified value Correct the coolant level and find out the cause of the loss Coolant p 225 If you had to add more coolant than the specified amount 0 20 l 0 21 qt Fill bleed the cooling system p 180 Mount the radiator cap ...

Страница 181: ...In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact ...

Страница 182: ... 16 5 Filling bleeding the cooling system Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly wit...

Страница 183: ...Guideline 3 turns Tilt the vehicle slightly to the right Pour in coolant until it emerges without bubbles at the bleeder screw and then mount and tighten the bleeder screw immedi ately Coolant p 225 Completely fill the radiator with coolant Mount the radiator cap Rest the vehicle on the side stand ...

Страница 184: ...aust extraction when starting or running the engine in an enclosed space Start the engine and let it warm up K00741 11 Stop the engine and allow it to cool down When the engine is cool check the coolant level in the radiator and if necessary add coolant Remove the cap of compensating tank 3 and top up the coolant level up to the MAX marking Mount the cap of the compensating tank Finishing work Fit...

Страница 185: ...cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the ev...

Страница 186: ...sition an appropriate container under the engine Remove screw 1 with the seal ring Remove the radiator cap Completely drain the coolant Mount and tighten screw 1 with a new seal ring Guideline Screw plug water pump drain hole M6 10 Nm 7 4 lbf ft E01179 10 Remove radiator cap 2 ...

Страница 187: ...ediately Coolant p 225 Completely fill the radiator with coolant Mount the radiator cap Rest the vehicle on the side stand Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Star...

Страница 188: ... down When the engine is cool check the coolant level in the radiator and if necessary add coolant Remove the cap of compensating tank 4 and top up the coolant level up to the MAX marking Mount the cap of the compensating tank Finishing work Fit the front spoiler p 120 ...

Страница 189: ...ot meet specifications Adjust the throttle cable play p 188 Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Start the engine and let it run at idle speed Move the handle bar t...

Страница 190: ...djuster 3 Guideline Throttle cable play 3 5 mm 0 12 0 2 in Tighten lock nut 2 Slide on sleeve 1 17 3 Checking the clutch lever play Note Clutch damage If there is no free travel by the clutch lever the clutch will begin to slip Check the free travel of the clutch lever each time before using the motorcycle Adjust the free travel of the clutch lever when necessary in accordance with the specificati...

Страница 191: ... is perceptible and deter mine the play in the clutch lever A Clutch lever play A 1 3 mm 0 04 0 12 in If the clutch lever play does not meet the specified value Adjust play in the clutch lever p 190 Move the handlebar to and fro over the entire steering range The clutch lever play must not change If the clutch lever play changes Check the routing of the clutch cable ...

Страница 192: ...h lever S00683 10 Move the handlebar to the straight ahead position Push back sleeve 1 Loosen lock nut 2 Adjust the play in the clutch level A by turning adjusting screw 3 Guideline Clutch lever play A 1 3 mm 0 04 0 12 in Tighten lock nut 2 Position bellows 1 ...

Страница 193: ...torcycle upright on a horizontal surface S00685 10 Main work Check the engine oil level Info After switching off the engine wait one minute before checking the level The engine oil must be between the markings A and B If the engine oil is below the marking A Add engine oil p 195 If the engine oil is above the marking B Correct the engine oil level ...

Страница 194: ...t of scalding rinse the area affected immediately with lukewarm water Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Drain the engine oil while the engine is at operating temperature Preparatory work Remove the front spoiler p 120 Place the...

Страница 195: ...in completely Clean the oil drain plug and the oil screen thoroughly Position oil screen 2 and mount and tighten oil drain plug 1 with the O ring Guideline Oil drain plug M24x1 5 15 Nm 11 1 lbf ft S04242 10 Remove screws 3 Take off oil filter cover 4 with the O ring Pull oil filter 5 out of the oil filter housing Allow the engine oil to drain completely Thoroughly clean the parts and the sealing s...

Страница 196: ... lbf ft Info Too little engine oil or poor quality engine oil will result in premature wear of the engine L02203 10 Remove filler plug 6 with the O ring and fill up with engine oil Engine oil Ambient tempera ture 0 50 C 32 122 F 1 5 l 1 6 qt Engine oil SAE 15W 50 p 226 Engine oil Ambient tempera ture 10 40 C 14 104 F Engine oil SAE 10W 40 p 227 Mount and tighten the filler plug together with the O...

Страница 197: ... sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Start the engine and check for leaks Finishing work Fit the front spoiler p 120 Check the engine oil level p 191 18 3 Adding engine oil Info Too little engine oil or poor quality engine oil will result in premature wear of the engine ...

Страница 198: ...o mix different engine oils We recommend changing the engine oil when neces sary Mount and tighten the filler plug together with the O ring Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an en...

Страница 199: ...SERVICE WORK ON THE ENGINE 18 197 Finishing work Check the engine oil level p 191 ...

Страница 200: ...ater jet directly on to electrical components connectors throttle cables or bearings Maintain a minimum distance between the nozzle of the pressure cleaner and the component Minimum clearance 60 cm 23 6 in Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regu...

Страница 201: ...oft sponge Never apply motorcycle cleaner to a dry motorcycle always rinse the vehicle with water first Clean the motorcycle with cold water if it has been used on salted roads Warm water enhances the cor rosive effects of salt After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the closure of the exhaust system Warning Danger of accidents Moisture and dirt ...

Страница 202: ...penetrated to evaporate After the motorcycle has cooled down lubricate all moving parts and pivot points Clean the chain p 112 Treat bare metal except for brake discs and the exhaust sys tem with a corrosion inhibitor Preserving materials for paints metal and rubber p 229 Treat all painted parts with a mild paint care product Perfect finish and high gloss polish for paints p 228 Info Do not polish...

Страница 203: ...29 Lubricate the ignition and steering lock Universal oil spray p 229 19 2 Checks and maintenance steps for winter operation Info If you use the motorcycle in winter you must expect salt on the roads You should therefore take precau tions against aggressive road salt Clean the motorcycle with cold water if it has been used on salted roads Warm water enhances the corro sive effects of salt ...

Страница 204: ...ers and brake linings after they have cooled down and without removing them with cold water and dry carefully Treat the engine the link fork and all other bare or zinc plated parts except the brake discs with a wax based corrosion inhibitor Info Corrosion inhibitor must not come in contact with the brake discs as this would greatly reduce the braking force Clean the chain p 112 ...

Страница 205: ... the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 228 Refuel p 93 Clean the motorcycle p 198 Change the engine oil and oil filter clean the oil screen p 192 Check the antifreeze and coolant level p 176...

Страница 206: ...torcycle with the rear lifting gear p 103 Lift the motorcycle with the front lifting gear p 104 Cover the motorcycle with a tarp or cover that is permeable to air Info Do not use non porous materials since they prevent humidity from escaping thus causing corrosion Avoid running the engine for a short time only Since the engine cannot warm up properly the water vapor produced during combustion cond...

Страница 207: ...059 01 Take the motorcycle off the front lifting gear p 106 Remove the rear of the motorcycle from the lifting gear p 103 Install the 12 V battery p 155 Set the clock p 70 Perform checks and maintenance measures when preparing for use p 80 Take a test ride ...

Страница 208: ... Shift the transmission into neutral Engine turns but does not start Operating error Carry out start procedure p 81 Malfunction in the electronic fuel injection Read out the fault memory using the KTM diagnostics tool Engine has too little power Air filter is very dirty Change the air filter Fuel filter is very dirty Check the fuel pressure Malfunction in the electronic fuel injection Read out the...

Страница 209: ... individual power consumers p 162 The ABS warning lamp lights up ABS fuse blown Change the ABS fuses p 159 Large difference in wheel speeds of the front and rear wheels Stop the vehicle switch off the igni tion and start it again Malfunction in ABS Read out the fault memory using the KTM diagnostics tool High oil consumption Engine vent hose bent Route the vent hose without bends or change it if n...

Страница 210: ...ged Ignition was not switched off when vehicle was parked Charge the 12 V battery p 156 The 12 V battery is not being charged by the alternator Check the charging voltage Check the open circuit current Combination instrument shows nothing on the display Fuse 8 is blown Change the fuses of individual power consumers p 162 Set the clock p 70 Speedometer in combination instrument not functioning Spee...

Страница 211: ... mm 0 94 in Valve clearance 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 Two ball bearings Conrod bearing Sleeve bearing Pistons Cast light alloy Piston rings 1 compression ring 1 tapered compression piston ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with 1 trochoidal pump Primary transmissio...

Страница 212: ...tion Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V 230 W Spark plug BOSCHVR5NEU Spark plug electrode gap 1 mm 0 04 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 450 1 550 rpm Starting aid Starter motor 22 2 Engine tightening torques Oil nozzle M5 6 Nm 4 4 lbf ft Loctite 243 ...

Страница 213: ...8 9 lbf ft Nut water pump impeller M6 10 Nm 7 4 lbf ft Loctite 243 Screw plug water pump drain hole M6 10 Nm 7 4 lbf ft Screw alternator cover M6 12 Nm 8 9 lbf ft Screw bearing retainer M6 12 Nm 8 9 lbf ft Loctite 243 Screw camshaft bearing bridge M6 10 Nm 7 4 lbf ft Screw chain securing guide M6 10 Nm 7 4 lbf ft Loctite 243 Screw clutch cable retaining bracket M6 6 Nm 4 4 lbf ft Loctite 243 Screw...

Страница 214: ... 8 9 lbf ft Loctite 243 Screw retaining bracket M6 12 Nm 8 9 lbf ft Loctite 243 Screw retaining bracket radial shaft seal ring clutch cover M6 12 Nm 8 9 lbf ft Loctite 243 Screw shift drum locating M6 12 Nm 8 9 lbf ft Loctite 243 Screw starter motor M6 12 Nm 8 9 lbf ft Screw timing chain tensioner M6 12 Nm 8 9 lbf ft Screw timing chain tensioning rail M6 12 Nm 8 9 lbf ft Loctite 243 Screw valve co...

Страница 215: ...nt temperature sensor M10 14 Nm 10 3 lbf ft Oil pressure sensor M10 14 Nm 10 3 lbf ft Rotor screw M10 70 Nm 51 6 lbf ft Loctite 243 Screw cylinder head M10 Step 1 25 Nm 18 4 lbf ft Step 2 50 Nm 36 9 lbf ft Thread is oiled head flat is greased Screw plug cam lever axis M10x1 10 Nm 7 4 lbf ft Spark plug M12 15 Nm 11 1 lbf ft Nut inner clutch hub M14LH 60 Nm 44 3 lbf ft Loctite 243 Nut primary gear w...

Страница 216: ... oil Ambient temperature 0 50 C 32 122 F 1 5 l 1 6 qt Engine oil SAE 15W 50 p 226 Engine oil Ambient temperature 10 40 C 14 104 F Engine oil SAE 10W 40 p 227 22 3 2 Coolant Coolant 1 l 1 qt Coolant p 225 22 3 3 Fuel Total fuel tank capacity approx 11 l 2 9 US gal Super unleaded ROZ 95 RON 95 PON 91 p 227 Fuel reserve approx 1 5 l 1 6 qt ...

Страница 217: ...liper rear Disc brake with single pot brake caliper floating Brake discs diameter front 300 mm 11 81 in rear 230 mm 9 06 in Brake discs wear limit front 4 5 mm 0 177 in rear 3 6 mm 0 142 in Tire pressure when solo front 2 0 bar 29 psi rear 2 0 bar 29 psi Tire pressure with passenger full payload front 2 0 bar 29 psi rear 2 2 bar 32 psi Secondary ratio 14 42 Chain 5 8 x 1 4 520 X ring ...

Страница 218: ...ble rear axle load 210 kg 463 lb Maximum permissible overall weight 335 kg 739 lb 22 5 Electrical system 12 V battery ETZ 9 BS Battery voltage 12 V Nominal capacity 8 Ah Maintenance free Fuse 75011088010 10 A Fuse 75011088015 15 A Fuse 90111088025 25 A Fuse 75011088030 30 A Headlight H4 socket P43t 12 V 60 55 W Position light W5W socket W2 1x9 5d 12 V 5 W Combination instrument lighting and indica...

Страница 219: ...s Front tire Rear tire 110 70 R 17 M C 54S TL MRF REVZ FC 150 60 R 17 M C 66S TL MRF REVZ C The tires specified represent one of the possible series production tires Additional information is available in the Service section under http www ktm com 22 7 Fork Fork article number F20123401O Fork WP Suspension Fork length 755 mm 29 72 in ...

Страница 220: ...EJOT PT K60x30 7 Nm 5 2 lbf ft Remaining screws chassis M4 4 Nm 3 lbf ft Remaining nuts chassis M5 5 Nm 3 7 lbf ft Remaining screws chassis M5 5 Nm 3 7 lbf ft Screw chain guard M5 7 Nm 5 2 lbf ft Loctite 243 Screw compensating tank cap lock rear brake M5 9 Nm 6 6 lbf ft Screw fuel tank cover M5 4 Nm 3 lbf ft Screw outer clutch cable guide M5 5 Nm 3 7 lbf ft Loctite 243 Screw side stand sensor M5 5...

Страница 221: ... filter box M6 6 Nm 4 4 lbf ft Screw brake fluid reservoir for rear brake M6 8 Nm 5 9 lbf ft Loctite 243 Screw brake hose clamp M6 7 Nm 5 2 lbf ft Screw chain sliding guard M6 7 Nm 5 2 lbf ft Screw combination instrument M6 7 Nm 5 2 lbf ft Screw compensating tank M6 5 Nm 3 7 lbf ft Screw damper block M6 8 Nm 5 9 lbf ft Screw engine sprocket cover M6 8 Nm 5 9 lbf ft Screw foot brake cylinder M6 9 N...

Страница 222: ...9 lbf ft Screw ignition lock tamper proof screw M6 13 Nm 9 6 lbf ft Screw license plate holder M6 12 Nm 8 9 lbf ft Loctite 243 Screw lower rear panel M6 7 Nm 5 2 lbf ft Screw magnetic holder on side stand M6 5 Nm 3 7 lbf ft Loctite 243 Screw main silencer M6 12 Nm 8 9 lbf ft Screw main silencer retaining bracket M6 9 Nm 6 6 lbf ft Screw protective plate M6 8 Nm 5 9 lbf ft Screw radiator holder M6 ...

Страница 223: ... rear sprocket M8 27 Nm 19 9 lbf ft Remaining nuts chassis M8 25 Nm 18 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft Screw bottom triple clamp M8 12 Nm 8 9 lbf ft Screw engine bearer M8 22 Nm 16 2 lbf ft Screw foot brake lever M8 16 Nm 11 8 lbf ft Loctite 243 Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 30 Nm 22 1 lbf ft Loctite 2701 Screw front brake disc M8 30 Nm 22...

Страница 224: ...M8 21 Nm 15 5 lbf ft Loctite 243 Screw rear seat fixing M8 18 Nm 13 3 lbf ft Screw seat support plate M8 18 Nm 13 3 lbf ft Screw subframe M8 25 Nm 18 4 lbf ft Loctite 620 Screw top triple clamp M8 15 Nm 11 1 lbf ft Banjo bolt brake line M10 24 Nm 17 7 lbf ft Fitting side stand M10 35 Nm 25 8 lbf ft Loctite 243 Remaining nuts chassis M10 45 Nm 33 2 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf...

Страница 225: ...ont footrest bracket M10x1 25 44 Nm 32 5 lbf ft Loctite 243 Screw front footrest bracket engine bearer M10x1 25 49 Nm 36 1 lbf ft Screw top shock absorber M10x1 25 51 Nm 37 6 lbf ft Loctite 243 Stud rear sprocket M10x1 25 50 Nm 36 9 lbf ft Nut rear wheel spindle M14x1 5 98 Nm 72 3 lbf ft Nut swingarm pivot M14x1 5 98 Nm 72 3 lbf ft Screw steering head top M16x1 5 49 Nm 36 1 lbf ft Loctite 243 Lamb...

Страница 226: ...22 TECHNICAL DATA 224 Nut steering head M30x1 1st stage 45 Nm 33 2 lbf ft 2nd stage loosen counterclock wise 2 turns 3rd stage 5 Nm 3 7 lbf ft ...

Страница 227: ... 1 Coolant Guideline Only use high grade silicate free coolant with corrosion inhibitor additive for aluminum motors Low grade and unsuitable antifreeze causes corrosion deposits and frothing Do not use pure water as only coolant is able to meet the requirements needed in terms of corrosion protec tion and lubrication properties Only use coolant that complies with the requirements stated see speci...

Страница 228: ...ns for antifreeze protection dilution and miscibility compatibility with other coolants Recommended supplier MOTOREX COOLANT M3 0 Engine oil SAE 15W 50 Standard classification JASO T903 MA2 p 230 SAE p 230 SAE 15W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Semi synthetic engine oil Rec...

Страница 229: ...ponding properties Semi synthetic engine oil Recommended supplier MOTOREX Formula 4T Super unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or ...

Страница 230: ...n Clean Fuel additive Recommended supplier MOTOREX Fuel Stabilizer Long life grease Recommended supplier MOTOREX Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX Moto Clean Perfect finish and high gloss polish for paints Recommended supplier MOTOREX Moto Shine ...

Страница 231: ...ier MOTOREX Moto Protect Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Street chain spray Guideline Recommended supplier MOTOREX Chainlube Road Strong Universal oil spray Recommended supplier MOTOREX Joker 440 Synthetic ...

Страница 232: ...ice intervals are demanded for automobile engines the focus for motorcycle engines is on high performance at high engine speeds In most motorcycle engines the transmission and clutch are lubricated with the same oil The JASO T903 MA2 standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils accordin...

Страница 233: ...ock braking system Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces OBD On board diagnosis Vehicle system which monitors the specified parame ters of the vehicle electronics ...

Страница 234: ...27 LIST OF ABBREVIATIONS 232 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Страница 235: ...horized KTM workshop The general warning lamp flashes yellow A note warning note on operating safety has been detected This is also shown in the display ABS warning lamp lights up yellow Status or error messages relating to ABS 28 2 Green and blue symbols Green and blue symbols reflect information The turn signal indicator lamp flashes green simultaneously with the turn signal The turn signal is s...

Страница 236: ...ng system 122 Applying the brakes 88 Auxiliary substances 23 B Brake discs checking 124 Brake fluid front brake adding 127 of rear brake adding 132 Brake fluid level front brake checking 126 of rear brake checking 131 Brake linings front brake checking 130 rear brake checking 135 Brakes 88 C Capacity coolant 214 engine oil 194 214 fuel 95 214 Chain chain dirt accumulation checking 112 checking 117...

Страница 237: ...display 56 fuel level display 57 function buttons 59 indicator lamps 52 ODO display 61 overview 46 range riding time menu 68 riding time average speed menu 64 service range menu 67 shift warning light 54 TRIP 1 display 62 TRIP 2 display 63 TRIP F display 60 warnings 48 Coolant draining 179 Coolant level checking 174 176 Cooling system 172 filling bleeding 180 Customer service 24 D Diagnostics conn...

Страница 238: ... rider s seat mounting 111 removing 110 Front spoiler installing 120 removing 120 Front wheel installing 141 removing 140 Fuel tank filler cap closing 40 opening 38 Fuel oils etc 23 Fuse of the individual consumers changing 162 G Grab handles 42 H Hand brake lever 32 Headlight bulb changing 165 Headlight range adjusting 169 Headlight setting checking 168 High beam flasher button 34 Horn button 33 ...

Страница 239: ...ving the rear from the lifting gear 103 taking off front lifting gear 106 O Oil filter changing 192 Oil screen cleaning 192 Owner s Manual 22 P Parking 90 Passenger foot pegs 42 Passenger seat mounting 110 removing 109 Play in the clutch lever adjusting 190 Preparing for use advice on preparing for first use 75 after storage 205 checks and maintenance measures when preparing for use 80 Protective ...

Страница 240: ...ng 84 Shock absorber spring preload adjusting 100 Side stand 44 Spare parts 23 Start button 36 Starting 81 Steering locking 37 unlocking 38 Steering lock 36 Stopping 90 Storage 203 T Technical data capacities 214 chassis 215 chassis tightening torques 218 electrical system 216 engine 209 fork 217 shock absorber 218 tightening torques engine 210 tires 217 Throttle cable play adjusting 188 checking ...

Страница 241: ...et 41 Transport 92 Troubleshooting 206 208 Turn signal bulb changing 169 Turn signal switch 35 Type label 30 U Use definition 10 V Vehicle identification number 30 View of vehicle front left 26 rear right 28 W Winter operation checks and maintenance steps 201 Work rules 21 ...

Страница 242: ... 3214156en 3214156en 04 2020 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KISKA KTM ...

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