KTM 1290 SUPERDUKE R Owner's Manual
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KTM 1290 SUPERDUKE R Owner's Manual

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OWNER'S MANUAL
2016
1290 Super Duke R
Art. no. 3213400en

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Summary of Contents for KTM 1290 SUPERDUKE R

  • Page 1 OWNER'S MANUAL 2016 1290 Super Duke R Art. no. 3213400en...
  • Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.
  • Page 4 Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SERIAL NUMBERS ............28 TABLE OF CONTENTS MEANS OF REPRESENTATION ........7 Chassis number ..........28 Symbols used ............7 Type label ............28 Formats used............8 Key number............29 SAFETY ADVICE.............. 9 Engine number ..........30 Use definition - intended use ........
  • Page 6 TABLE OF CONTENTS 6.13 Supporting strap ..........43 7.9.14 "Temp" ............60 6.14 Helmet lock............43 7.9.15 "Pressure" ............. 61 6.15 Passenger footrests ..........44 7.9.16 "Fuel Cons" ........... 61 6.16 Shift lever ............44 7.9.17 "Clock/Date" ..........62 6.17 Foot brake lever ..........
  • Page 7 TABLE OF CONTENTS 10.6 Stopping, parking..........82 13.9 Mounting the helmet lock on the vehicle .... 101 10.7 Transport ............83 13.10 Disassembling the main silencer ....102 10.8 Refueling ............84 13.11 Installing the main silencer ......104 11 SERVICE SCHEDULE ............ 86 13.12 Checking the chain for dirt........
  • Page 8 TABLE OF CONTENTS 16.2 Removing the battery ........135 22 TROUBLESHOOTING ..........179 16.3 Installing the battery ........137 23 TECHNICAL DATA............181 16.4 Recharging the battery ........140 23.1 Engine ............181 16.5 Changing the main fuse ........144 23.2 Engine tightening torques .........

  • Page 9: Means Of Representation

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

  • Page 10: Formats Used

    MEANS OF REPRESENTATION Formats used The typographical formats used in this document are explained below. Specific name Identifies a proprietary name. Name ® Identifies a protected name. Brand™ Identifies a brand available on the open market. Underlined terms Refer to technical details of the vehicle or indicate technical terms that are explained in the glossary.

  • Page 11: Safety Advice

    SAFETY ADVICE Use definition - intended use KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation and also for use on race courses, but not for offroad use. Info The motorcycle is only authorized for operation on public roads in the homologated version.

  • Page 12: Degrees Of Risk And Symbols

    SAFETY ADVICE Degrees of risk and symbols Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.

  • Page 14: Overview Of Labels

    SAFETY ADVICE Overview of labels L01488-10...
  • Page 15 SAFETY ADVICE Type label for USA Type label for Canada Information on suspension setting Information on chain tension Technical Information Information on preparations for use Information on noise emissions Information on emissions control C00936-01 Type label for USA...
  • Page 16 SAFETY ADVICE C00937-01 Type label for Canada Information on suspension setting L01470-01...
  • Page 17 SAFETY ADVICE Information on chain tension L01472-01 L01475-01 Technical Information...
  • Page 18 SAFETY ADVICE Information on preparations for use L01471-01 C00938-01 Information on noise emissions...

  • Page 19: Reporting Safety Defects

    Noise emission warranty KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.

  • Page 20: Operating Noise Warning

    Otherwise, the owner may become subject to penalties under the applicable ordinances. Consumer rights Warranty claims should be submitted to a KTM workshop. If you are not satisfied, please contact: KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA Phone: (440) 985–3553...

  • Page 21: Safe Operation

    The vehicle should only be used by trained persons. 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.

  • Page 22: Protective Clothing

    Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. 2.12 Work rules Special tools are necessary for certain tasks.

  • Page 23: Owner's Manual

    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.

  • Page 24: Important Notes

    Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the warranty.

  • Page 25: Service

    Please follow the instructions in the text. Customer service Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM. A list of authorized KTM dealers can be found on the KTM website.

  • Page 26: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) L01493-10...
  • Page 27 VIEW OF VEHICLE Clutch lever ( p. 32) Supporting strap ( p. 43) Tool set ( p. 42) Seat lock ( p. 41) Passenger footrests ( p. 44) Rider footrests Shift lever ( p. 44) Side stand ( p. 46) Shock absorber, spring preload setting Cooling system compensating tank Engine oil level viewer...

  • Page 28: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) L01491-10...
  • Page 29 VIEW OF VEHICLE Filler cap Combination switch ( p. 33) Ignition/steering lock ( p. 37) Fork compression adjustment Emergency OFF switch ( p. 36) Electric starter button ( p. 37) Throttle grip ( p. 33) Hand brake lever ( p. 32) Fork rebound adjustment Foot brake lever ( p.

  • Page 30: Serial Numbers

    SERIAL NUMBERS Chassis number  The chassis number is stamped on the right side of the steering head. The chassis number is also shown on the type label. 402324-10 Type label  The type label USA is located on the steering head on the left. 0 0 1 402302-10...

  • Page 31: Key Number

    SERIAL NUMBERS The type label Canada  is located on the frame on the left. 402293-10 Key number Key number Code number  can be found on the KEYCODECARD. Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place.

  • Page 32: Engine Number

    SERIAL NUMBERS Engine number  The engine number is stamped on the right side of the engine. 402296-10 Fork part number  The fork part number is stamped on the inside of the axle clamp. 402295-10...

  • Page 33: Shock Absorber Article Number

    SERIAL NUMBERS Shock absorber article number  The shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 402298-10 Steering damper article number  Steering damper item number is embossed on the underside of the steering damper. H01060-10...

  • Page 34: Controls

    CONTROLS Clutch lever  Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automatically. L01405-10 Hand brake lever  The hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever.

  • Page 35: Throttle Grip

    CONTROLS Throttle grip  The throttle grip is fitted on the right side of the handlebar. L01408-10 Switches on the left side of the handlebar 6.4.1 Combination switch The combination switch is fitted on the left side of the handlebar. Overview of the left combination switch Light switch ( p.

  • Page 36: Light Switch

    CONTROLS 6.4.2 Light switch  The light switch is fitted on the combination switch on the left. Possible states Low beam on – Light switch in position  . In this position, the low beam and tail light are switched on. High beam on –...

  • Page 37: Menu Switch

    CONTROLS 6.4.4 Menu switch The menu switch is fitted in the middle of the left combination switch. The menu buttons are used to control the matrix display on the combination instrument.  Button is the UP button.  Button is the DOWN button. ...

  • Page 38: Horn Button

    CONTROLS 6.4.6 Horn button  The horn button is fitted on the combination switch on the left. Possible states • Horn button in basic position. pressed – The horn is operated in this position. • Horn button L01406-14 Switches on the right side of the handlebar 6.5.1 Emergency OFF switch ...

  • Page 39: Electric Starter Button

    CONTROLS 6.5.2 Electric starter button  The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position. is pressed – In this position, the electric starter is actuated. • Electric starter button L01409-11 Ignition/steering lock...

  • Page 40: Immobilizer

    The black ignition keys are activated when delivered. Another two spare ignition keys (key number on the KEYCODECARD) can be ordered from an authorized KTM workshop; they need to be activated for use. Opening the filler cap Danger Fire hazard Fuel is highly flammable.
  • Page 41 CONTROLS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water.

  • Page 42: Closing The Filler Cap

    CONTROLS Note Danger of damage Ignition key breakage. – To take pressure off of the ignition key, push down on the filler cap. Damaged igni- tion keys must be replaced. –  Turn ignition key clockwise. – Fold open filler cap ...

  • Page 43: Seat Lock

    CONTROLS – Press down the filler cap and turn back ignition key  until the fuel tank lock locks. Warning Fire hazard Fuel is highly flammable, poisonous and harmful to your health. – After closing the filler cap, ensure that it is locked properly. Change cloth- ing that has been contaminated with fuel.

  • Page 44: Baggage Lugs

    CONTROLS 6.11 Baggage lugs  The baggage lugs are located on the bottom of the passenger seat. Info When the passenger seat is mounted, the lugs are accessible if they are turned out- ward. No more than one small piece of luggage with the specified weight may be attached to the turned-out baggage lugs.

  • Page 45: Supporting Strap

    CONTROLS 6.13 Supporting strap  The supporting strap is attached to the passenger seat. The supporting strap is provided for the passenger to hold on to. L01448-10 6.14 Helmet lock Warning Danger of accidents Impairment of vehicle handling and vehicle operation if a hel- met or helmet lock is attached to the vehicle.

  • Page 46: Passenger Footrests

    CONTROLS 6.15 Passenger footrests The passenger footrests 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. • L01411-10 6.16 Shift lever ...

  • Page 47: Foot Brake Lever

    CONTROLS The gear positions can be seen in the figure. The idle position is between the first and second gears. 402299-11 6.17 Foot brake lever  Foot brake lever is located in front of the right footrest. The rear brake is engaged with the foot brake lever. 402301-10...

  • Page 48: Side Stand

    CONTROLS 6.18 Side stand  The side stand is located on the left side 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; see the instructions in the "Stopping, parking"...

  • Page 49: Combination Instrument

    COMBINATION INSTRUMENT Overview Matrix display ( p. 48) Tachometer Shift warning light ( p. 51) Segment display indicator lamps ( p. 49) 401800-10 activation and test Activation The combination instrument 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.

  • Page 50: Matrix Display

    COMBINATION INSTRUMENT Matrix display The matrix display is controlled using the menu switch ( p. 35). After the ignition is switched on, the display shows when the next service ( p. 52) is due. If the General warning lamp lights up among the indicator lamps ( p.

  • Page 51: Indicator Lamps

    COMBINATION INSTRUMENT indicator lamps Possible states The high beam indicator lamp lights up blue – The high beam is switched The immobilizer indicator lamp lights up or flashes red – Status or error message for immobilizer/alarm system. The oil pressure warning lamp lights up red – Engine oil pressure is too low.

  • Page 52: Message On The Matrix Display

    KTM workshop. General message – General message on operating safety. Visit an autho- rized KTM workshop. ABS warning – ABS is not available. Visit an authorized KTM workshop. Traction control – Traction control is not available. Visit an authorized KTM 401850-01 workshop.

  • Page 53: Shift Warning Light

    COMBINATION INSTRUMENT Service – A service is due. Contact an authorized KTM workshop. Emergency OFF switch – The emergency OFF switch is off. The messages are displayed in the "Warning" menu. Shift warning light The shift warning light flashes or lights up when the transmission should be shifted.

  • Page 54: Service Display

    COMBINATION INSTRUMENT Service display After the ignition is switched on, the service display appears briefly. The service intervals depend on the distance traveled or the elapsed time. The event that occurs first applies. The exact service intervals can be found in the service schedule. 401821-01 Matrix display menu 7.9.1...

  • Page 55: Trip 1

    COMBINATION INSTRUMENT 7.9.2 "Trip 1" – Press the UP or DOWN button until the "Trip 1" menu appears on the matrix display. "Trip 1" shows the distance since the last reset, such as between two refueling stops. "Trip 1" runs continuously and counts the distance up to 9999. "Ø...

  • Page 56: General Info

    COMBINATION INSTRUMENT 7.9.4 "General Info" – Press the UP oder DOWN button until the "General Info" menu appears on the matrix dis- play. "Air Temp" indicates the ambient air temperature. "Date" indicates the date. "ODO" indicates the total distance covered. "Battery"...

  • Page 57: Settings

    COMBINATION INSTRUMENT 7.9.6 "Settings" 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 menu. Settings for units or various values are made in the "Settings" menu. Several functions can be enabled or disabled.

  • Page 58: Heating" (Optional)

    COMBINATION INSTRUMENT 7.9.8 "Heating" (optional) – Press UP or DOWN button until the "Heating" menu appears on the matrix display. Press- ing the SET button opens the menu. – Use the SET button to select a heating level or to switch off the heated grips. 402434-02 7.9.9 "MTC/ABS"...

  • Page 59: Drive Mod

    COMBINATION INSTRUMENT 7.9.10 "Drive Mod" – Press the UP or DOWN button until the "Drive Mod" menu appears on the matrix display. Pressing the SET button opens the menu. – Use the UP or DOWN button to navigate through the menu. The SET button can be used to select engine and traction control settings that are coordinated with each other.

  • Page 60: Menu Overview

    COMBINATION INSTRUMENT 7.9.11 Menu overview L01438-10...

  • Page 61: Language

    COMBINATION INSTRUMENT KTM start screen Menu buttons "Favorites" "Trip 1" "Trip 2" "General Info" "Set Favorites" "Settings" "Warning" (only active if there are messages) "Heat Grip" (optional) "MTC/ABS" "Drive Mod" 7.9.12 "Language" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the matrix display.

  • Page 62: Distance

    COMBINATION INSTRUMENT 7.9.13 "Distance" 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 menu. – Press the UP or DOWN button until "Distance" is highlighted in black on the matrix dis- play.

  • Page 63: Pressure

    COMBINATION INSTRUMENT 7.9.15 "Pressure" 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 menu. – Press the UP or DOWN button until "Pressure" is highlighted in black on the matrix dis- play.

  • Page 64: Clock/Date

    COMBINATION INSTRUMENT 7.9.17 "Clock/Date" 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 menu. – Press the UP or DOWN button until "Clock/Date" is highlighted in black on the matrix dis- play.

  • Page 65: Heat Grip

    COMBINATION INSTRUMENT 7.9.19 "Heat Grip" 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 menu. – Press the UP or DOWN button until "Heat Grip" is highlighted in black on the matrix dis- play.

  • Page 66: Ergonomics

    The handlebar can be mounted in two different positions. In this way, the handlebar can be mounted in the most comfortable position for the rider. Info KTM recommends the front handlebar position when using the vehicle on a race track. 402000-11...

  • Page 67: Setting The Basic Setting Of The Clutch Lever

    ERGONOMICS Guideline Screw, instrument support 40 Nm Loctite ® 243™ (29.5 lbf ft) – Position the handlebar. Info Make sure the cables and wiring are positioned correctly. –  Position the handlebar clamp. Mount and evenly tighten screws Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) Setting the basic setting of the clutch lever...

  • Page 68: Adjusting The Basic Position Of The Hand Brake Lever

    ERGONOMICS Adjusting the basic position of the hand brake lever – Adjust the basic position of the hand brake lever to your hand size by turning adjusting  wheel Info Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar.

  • Page 69: Setting The Step Plate Of The Foot Brake Lever

    ERGONOMICS Setting the step plate of the foot brake lever –  Remove screw together with the foot plate of the foot brake lever. – To adjust the length of the foot brake lever, position the step plate of the foot brake ...

  • Page 70: Adjusting The Basic Position Of The Shift Lever

    ERGONOMICS – Sit on the vehicle in the riding position and determine distance  between the upper edge of your boot and the shift lever. Distance between shift lever and upper 10… 20 mm (0.39… 0.79 in) edge of boot »...

  • Page 71: Setting The Shift Lever Stub

    ERGONOMICS – Tighten nut  , holding the threaded rod  Guideline Nut, shift rod M8LH 12 Nm (8.9 lbf ft) Setting the shift lever stub –  Remove screw along with the shift lever stub. –  Position the shift lever stub with the screw in one of the drilled holes depending on the desired lever length.

  • Page 72: Preparing For Use

    The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning Danger of accidents Uncontrollable 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 accidents Reduced road grip with new tires. –...

  • Page 73: Running In The Engine

    When using your vehicle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.

  • Page 74: Loading The Vehicle

    PREPARING FOR USE During the running-in phase, set the shift warning light to the specified engine speed. – Avoid fully opening the throttle! Loading the vehicle Warning Danger of accidents Unstable handling characteristics. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage.
  • Page 75 PREPARING FOR USE Warning Danger of accidents Changed handling characteristics and longer stopping distance with excessive payload. – Adapt your speed according to your payload. Warning Danger of accidents Unstable handling characteristics due to slipped baggage. – Check the way your baggage is fixed regularly. Warning Danger of burns A hot exhaust system can burn baggage.

  • Page 76: Riding Instructions

    RIDING INSTRUCTIONS 10.1 Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is roadworthy. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 77: Starting

    RIDING INSTRUCTIONS 10.2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 78: Starting Off

    RIDING INSTRUCTIONS – Press the electric starter button Info Do not press the electric starter button until the combination instrument func- tion check is finished. When starting, DO NOT open the throttle. If you open the throttle during the start- ing procedure, fuel is not injected by the engine management system and the engine cannot start.
  • Page 79 RIDING INSTRUCTIONS Warning Danger of accidents Malfunctions caused by incorrect ignition key position. – Do not change the ignition key position during a journey. Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle. – Make all adjustments when the vehicle is at a standstill. Warning Risk of injury Falling off of the passenger.
  • Page 80 If you continue with the coolant temperature warning lamp alight, you may have engine failure. Info If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized KTM workshop.
  • Page 81 Contact an authorized KTM workshop. – If the engine warning lamp lights up during a trip, please contact an authorized KTM workshop as soon as possible. Info From the flash rhythm you can deduce a two-digit number, the so-called blink code.

  • Page 82: Applying The Brakes

    Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. – Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Failure of brake system.
  • Page 83 RIDING INSTRUCTIONS Warning Danger of accidents Greater stopping distance due to ABS. – Braking should be appropriate to the driving situation and the road conditions. Warning Danger of accidents Very forceful braking can cause the wheels to block. – ABS must be switched on to be effective. Warning Danger of accidents Vehicle rollover –...

  • Page 84: Stopping, Parking

    RIDING INSTRUCTIONS – Use the braking effect of the engine on long downhill stretches. Change down one or two gears, but do not over-rev the engine. In this way, you have to brake far less and the brakes do not overheat. 10.6 Stopping, parking Warning...

  • Page 85: Transport

    RIDING INSTRUCTIONS – Shift the transmission to idle – Switch off the ignition by turning the black ignition key to the position OFF Info If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock, power continues to flow to most power consumers.

  • Page 86: Refueling

    Material damage Premature clogging of the fuel filter. – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.)
  • Page 87 RIDING INSTRUCTIONS – 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, the ground, or the sewage system. –...

  • Page 88: Service Schedule

    Every 30,000 km (18,600 mi) Every 15,000 km (9,300 mi) After 1,000 km (620 mi) ○ ● ● ● ● Read out the fault memory using the KTM diagnostics tool. ● ● ● ● Check the fuel pressure. ○ ●...
  • Page 89 ● Check the CO adjustment with the KTM diagnostics tool. ○ ● ● ● ● Reset the service interval display. ○ ● ● ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet.

  • Page 90: Recommended Work

    SERVICE SCHEDULE ○ One-time interval ● Periodic interval 11.3 Recommended work Every four years Every two years Every year Every 15,000 km (9,300 mi) After 1,000 km (620 mi) ○ ● Check/clean the oil nozzle for clutch lubrication. ● Check the swingarm bearing. ●...

  • Page 91: Suspension Setting

    SUSPENSION SETTING 12.1 Fork/shock absorber The fork and the shock absorber offer many options of adapting the suspension to the riding style and the payload. Info  The recommendations for the suspension setting are shown in Table . The table is located on the underside of the front rider's seat.

  • Page 92: Adjusting The Rebound Damping Of The Fork

    SUSPENSION SETTING Guideline Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 12.3 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. –...

  • Page 93: Compression Damping Of The Shock Absorber

    SUSPENSION SETTING Guideline Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 12.4 Compression damping of the shock absorber The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.

  • Page 94: Adjusting The Low-Speed Compression Damping Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber.

  • Page 95: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber.

  • Page 96: Adjusting The Rebound Damping Of The Shock Absorber

    Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) – ...
  • Page 97 SUSPENSION SETTING Info The spring preload defines the initial situation of the spring process 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 luggage and a passenger, thus ensuring an ideal compromise between maneuverability and stability.
  • Page 98 SUSPENSION SETTING – Tighten the spring by turning adjusting ring  to the specified measurement  Guideline Spring preload Comfort 5 mm (0.2 in) Standard 5 mm (0.2 in) Sport 6 mm (0.24 in) Full payload 7 mm (0.28 in) Info Turn clockwise to increase the spring preload;...

  • Page 99: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 13.1 Lifting the motorcycle with the rear lifting gear Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Place the adapter into the rear lifting gear. Lifting gear, rear (61329955000) –...

  • Page 100: Lifting The Motorcycle With The Front Lifting Gear

    SERVICE WORK ON THE CHASSIS – Secure the motorcycle against falling over. –  Remove the rear wheel stand and lean the vehicle on side stand 402029-10 13.3 Lifting the motorcycle with the front lifting gear Note Danger of damage The parked vehicle may roll away or fall over. –...

  • Page 101: Taking The Motorcycle From The Front Lifting Gear

    SERVICE WORK ON THE CHASSIS 13.4 Taking the motorcycle from the front lifting gear Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Secure the motorcycle against falling over. –...

  • Page 102: Mounting The Passenger Seat

    SERVICE WORK ON THE CHASSIS 13.6 Mounting the passenger seat –  Attach the recesses of the passenger seat in the guides and lower at the front while pushing it back. –  Position locking pin in the lock housing and push down the passenger seat at the front.

  • Page 103: Mounting The Front Rider's Seat

    SERVICE WORK ON THE CHASSIS 13.8 Mounting the front rider's seat Main work –  Attach recesses on the front rider's seat to the fuel tank and push the front rider's seat forward while lowering it.  Catch is located in the recess. –...

  • Page 104: Disassembling The Main Silencer

    SERVICE WORK ON THE CHASSIS – Remove the passenger seat. ( p. 99) –   Position steel cable from the tool set with the loop around catch Steel cable (60012015000) – Pass the steel cable through the helmet opening. –...
  • Page 105 SERVICE WORK ON THE CHASSIS – Remove screw  with the washer. – Take off the main silencer. 202959-11 –  Remove seal ring 202960-11...

  • Page 106: Installing The Main Silencer

    SERVICE WORK ON THE CHASSIS 13.11 Installing the main silencer –  Mount seal ring 202960-10 – Position the main silencer. – Mount screw  with the washer but do not tighten yet. Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) 202959-11...

  • Page 107: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS – Position the exhaust clamp. –  Mount and tighten screw Guideline Screw, exhaust clamp on main silencer 8 Nm (5.9 lbf ft) –  Tighten screw Guideline Remaining screws, chassis 25 Nm (18.4 lbf ft) 202958-11 13.12 Checking the chain for dirt...
  • Page 108 SERVICE WORK ON THE CHASSIS Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 109: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 13.14 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bearings in the transmission and in the rear wheel) will be under additional load.

  • Page 110: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS – Check the locking caps  for damage and tightness. » If the locking caps are damaged or loose: – Replace locking caps. Link fork locking cap (61304041100) H00380-11 13.15 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension.
  • Page 111 SERVICE WORK ON THE CHASSIS Main work –  Loosen screw – Set the chain tension by turning the hub housing. Hook wrench (61329085000) Handle for ring wrench (60012060000) Info Turn clockwise to increase the chain tension; turn counterclockwise to reduce the chain tension.

  • Page 112: Checking The Chain, Rear Sprocket, Motor Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 13.16 Checking the chain, rear sprocket, motor sprocket, and chain guide – Check the rear sprocket and motor sprocket for wear. » If the rear sprocket or engine sprocket is worn: – Change the drivetrain kit. Info The motor sprocket, rear sprocket, and chain should always be replaced together.
  • Page 113 SERVICE WORK ON THE CHASSIS – Shift the transmission to idle –  Pull the lower chain section with specified weight Guideline Weight, chain wear measurement 15 kg (33 lb.) –  Measure the distance of 18 chain links in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at differ- ent chain positions.
  • Page 114 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear at the recess. »   When rivet of the chain is no longer visible at the bottom edge of the recess of the chain sliding guard: –...

  • Page 115: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated. »...
  • Page 116 SERVICE WORK ON THE CHASSIS – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Check the fluid level. The fluid level must be between the MIN and MAX markings. » If the fluid level does not meet specifications: –...

  • Page 117: Brake System

    KTM. – Service work and repairs must be performed properly. (Your authorized KTM workshop will be glad to help.) ABS is a safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces.
  • Page 118 BRAKE SYSTEM In the "SUP MOT" ABS mode, the ABS only controls the front wheel. There is no ABS intervention on the rear wheel. The ABS lamp  flashes slowly to remind you that the "SUP MOT" ABS mode is enabled. Info In the "SUP MOT"...

  • Page 119: Checking The Brake Discs

    Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at multiple points on each brake ...

  • Page 120: Checking The Brake Fluid Level Of The Front Brake

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
  • Page 121 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake 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.

  • Page 122: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. –...

  • Page 123: Checking The Rear Brake Fluid Level

    (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)

  • Page 124: Adding Rear Brake Fluid

    If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)
  • Page 125 BRAKE SYSTEM Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in 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.

  • Page 126: Checking The Brake Linings Of The Rear Brake

    Checking the brake linings of the rear brake Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. –...

  • Page 127: Wheels, Tires

    WHEELS, TIRES 15.1 Removing the front wheel Preparatory work – Lift the motorcycle with the rear lifting gear. ( p. 97) – Lift the motorcycle with the front lifting gear. ( p. 98) Main work –  Remove screws from both brake calipers. –...

  • Page 128: Installing The Front Wheel

    WHEELS, TIRES – Remove spacers  309489-10 15.2 Installing the front wheel – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the front wheel bearing. –   Clean and grease the shaft seal rings and mating surfaces of the spacers.
  • Page 129 WHEELS, TIRES – Insert the wide spacer  on the left in the direction of travel. Info  The arrow indicates the direction of travel of the front wheel. – Insert the narrow spacer on the right in the direction of travel. 309491-10 Warning Danger of accidents Reduced braking efficiency due to oil or grease on the...
  • Page 130 WHEELS, TIRES – Position the brake calipers and check that the brake linings are seated correctly. –  Mount screws on both brake calipers but do not tighten yet. – Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

  • Page 131: Removing The Rear Wheel

    WHEELS, TIRES 15.3 Removing the rear wheel Preparatory work – Lift the motorcycle with the rear lifting gear. ( p. 97) – Disassemble the main silencer. p. 102) Main work –  Remove the inside locking wire – Remove the outside locking wire ...

  • Page 132: Installing The Rear Wheel

    WHEELS, TIRES – Take off the rear wheel. 203022-10 15.4 Installing the rear wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Danger of accidents No braking effect when operating the rear brake.
  • Page 133 WHEELS, TIRES Main work – Check the rear wheel bearing for damage and wear. » If the rear wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease the threads of the wheel axle and axle nut. Long-life grease ( p.

  • Page 134: Checking The Tire Condition

    Danger of accidents Uncontrollable vehicle handling in the event of a flat tire. – In the interest of safety, replace damaged or worn tires immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
  • Page 135 WHEELS, TIRES Warning Danger of accidents Reduced road grip with new tires. – New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be rough- ened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved until the tires have been run in.

  • Page 136: Checking The Tire Air Pressure

    DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manufacture. KTM recommends that the tires be changed after 5 years at the latest, regard- less of the actual state of wear.

  • Page 137: Electrical System

    ELECTRICAL SYSTEM 16.1 Daytime running light (DRL) The daytime running light/parking light is integrated in the main headlight. The daytime running light can be switched on when visibility conditions are good. Activate the daytime running light in the combination instrument. Control is provided by the bright- ness sensor in the combination instrument.
  • Page 138 ELECTRICAL SYSTEM Preparatory work – Switch off all power consumers and switch off the engine. – Remove the passenger seat. ( p. 99) – Remove the front rider's seat. ( p. 100) Main work –  Remove screw – Lift cover ...

  • Page 139: Installing The Battery

    ELECTRICAL SYSTEM 16.3 Installing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...
  • Page 140 ELECTRICAL SYSTEM – Position the positive cable and mount and tighten the screw. Guideline Screw, battery terminal 4.5 Nm (3.32 lbf ft) –  Mount positive terminal cover –  Position negative cable and mount and tighten the screw. Guideline Screw, battery terminal 4.5 Nm L01483-11...
  • Page 141 ELECTRICAL SYSTEM – Position cover    Screw heads engage in recesses –  Mount and tighten screw L01486-10 Finishing work – Mount the front rider's seat. ( p. 101) – Mount the passenger seat. ( p. 100) – Set the time and date.

  • Page 142: Recharging The Battery

    – Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 143 The battery is maintenance-free, i.e., the acid level does not have to be checked. If the battery is not charged using the KTM battery charger, the battery must be removed for charging. Otherwise, overvoltage may damage electronic components. Charge the battery according to the instructions on the battery housing.
  • Page 144 ELECTRICAL SYSTEM – Disconnect negative cable  of the battery to avoid damage to the motorcycle's elec- tronics. – Remove positive terminal cover  L01483-12 – 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 and start potential of the battery, and to test the alternator.
  • Page 145 ELECTRICAL SYSTEM – Mount positive terminal cover  –  Position negative cable and mount and tighten the screw. Guideline Screw, battery terminal 4.5 Nm (3.32 lbf ft) L01483-12 –  Position cover   Screw heads engage in recesses –...

  • Page 146: Changing The Main Fuse

    ELECTRICAL SYSTEM Finishing work – Mount the front rider's seat. ( p. 101) – Mount the passenger seat. ( p. 100) – Set the time and date. 16.5 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. –...
  • Page 147 ELECTRICAL SYSTEM – Remove protection caps  500327-11 –  Remove the faulty main fuse Info  A defective fuse is indicated by a burned-out fuse wire  A spare fuse is located in the starter relay. The main fuse protects all power consumers of the vehicle. –...
  • Page 148 ELECTRICAL SYSTEM – Position cover    Screw heads engage in recesses –  Mount and tighten screw L01486-11 Finishing work – Mount the front rider's seat. ( p. 101) – Mount the passenger seat. ( p. 100) – Set the time and date.

  • Page 149: Changing The Fuses In The Fuse Box

    ELECTRICAL SYSTEM 16.6 Changing the fuses in the fuse box Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work –...
  • Page 150 ELECTRICAL SYSTEM – Open fuse box cover  S00322-10 – Check the fuses. Info  A defective fuse is indicated by a burned-out fuse wire – Remove the defective fuse. Guideline Fuse res - 10 A - spare fuses Fuse 1 - 10 A - power supply for control units and components C00934-10 Fuse 2 - 10 A - permanent positive for auxiliary equipment (ACC1) Fuse 3 - 15 A - ABS hydraulic unit...
  • Page 151 ELECTRICAL SYSTEM Fuse (58011109115) ( p. 187) Fuse (58011109125) ( p. 188) Insert a spare fuse so that it is available if needed. – Check that the power consumer is functioning properly. – Close the fuse box cover. –  Position cover ...

  • Page 152: Changing The Headlight Bulb

    ELECTRICAL SYSTEM Finishing work – Mount the front rider's seat. ( p. 101) – Mount the passenger seat. ( p. 100) 16.7 Changing the headlight bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.
  • Page 153 ELECTRICAL SYSTEM – Detach connector  –  Take off rubber cap 500335-10 –  Detach retaining clamp –  Remove bulb – Position the new bulb in the headlight housing. Low beam/high beam (H4/socket U37R) ( p. 188) Info Insert the headlight bulb so that the catches latch into the recesses.

  • Page 154: Changing The Turn Signal Bulb

    ELECTRICAL SYSTEM – Fold the headlight mask up. –  Mount and tighten screws Guideline Remaining screws, chassis 5 Nm (3.7 lbf ft) 500331-10 16.8 Changing the turn signal bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.

  • Page 155: Checking The Headlight Setting

    ELECTRICAL SYSTEM – Check that the turn signal is functioning properly. – Position the diffuser. Info Insert catch  into recess  – Insert the screw and first turn counterclockwise until it engages in the thread with a small jerk. Tighten the screw lightly. 16.9 Checking the headlight setting –...

  • Page 156: Adjusting The Headlight Range

    ELECTRICAL SYSTEM 16.10 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 153) Main work –  Using the cross-head screwdriver from the tool set, adjust the headlight range of the headlight. Cross-head screwdriver (53012024100) Info Turn clockwise to increase the headlight range;...

  • Page 157: Activating/Deactivating The Ignition Key

    ELECTRICAL SYSTEM 16.11 Activating/deactivating the ignition key Info The orange programming key must only be used for activating and deactivating! If a black ignition key is lost or needs to be replaced, the individual black ignition keys need to be enabled or disabled using the orange programming key.
  • Page 158 ELECTRICAL SYSTEM – Switch off the ignition by turning the black ignition key to the position OFF – Remove the black ignition key. – Insert the orange programming key in the ignition lock. – Switch on the ignition by turning the orange programming key to the position ON The immobilizer indicator lamp flashes according to the number of func- tional black ignition keys including the orange programming key.
  • Page 159 ELECTRICAL SYSTEM – Insert the orange programming key in the ignition lock. – Switch on the ignition by turning the orange programming key to the position ON Immobilizer indicator lamp lights up. – Switch off the ignition by turning the orange programming key to the position OFF –...
  • Page 160 ELECTRICAL SYSTEM – If the last black ignition key was activated, insert the orange programming key into the ignition lock. – Switch on the ignition by turning the orange programming key to the position ON The immobilizer indicator lamp flashes according to the number of func- tional black ignition keys including the orange programming key.
  • Page 161 ELECTRICAL SYSTEM Info After the fourth black ignition key has been activated, programming is fin- ished.

  • Page 162: Cooling System

    COOLING SYSTEM 17.1 Checking the coolant level in the compensating tank Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 163: Correcting The Coolant Level In The Compensating Tank

    COOLING SYSTEM – Correct the coolant level in the compensating tank. ( p. 161) 17.2 Correcting the coolant level in the compensating tank Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.
  • Page 164 COOLING SYSTEM Main work – Pull off the compensating tank toward the bottom and maneuver it out. L01487-10 –  Remove cover of the compensating tank. – Add coolant to the MAX marking. Coolant ( p. 196) – Mount the cover of the compensating tank. –...

  • Page 165: Engine Tuning

    ENGINE TUNING 18.1 "Drive Mod" Possible states SPORT – Homologated performance with very direct response; the traction control • allows greater slip on the rear wheel STREET – Homologated performance with balanced response; the traction control • allows normal slip on the rear wheel RAIN –...
  • Page 166 ENGINE TUNING Info When traction control is active, the TC lamp flashes. When traction control is switched off, the TC lamp is lit.

  • Page 167: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 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. Main work –...

  • Page 168: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens

    SERVICE WORK ON THE ENGINE 19.2 Changing the engine oil and oil filter, cleaning the oil screens Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 169 SERVICE WORK ON THE ENGINE – Remove screws  . Remove the oil filter cover  with the O-ring. 500339-10 –  Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) – Completely drain the engine oil. –...
  • Page 170 SERVICE WORK ON THE ENGINE – Mount and tighten screws  Guideline Remaining engine screws 6 Nm (4.4 lbf ft) 500342-10 –   Thoroughly clean magnet and oil screen of the oil drain plugs. 100773-12 –  Mount and tighten the oil drain plugs with the magnet, O-rings, and oil screen.
  • Page 171 SERVICE WORK ON THE ENGINE – Add the oil quantity in two separate operations. Engine oil 3.60 l (3.8 qt.) Outside Engine oil temperature: (SAE 10W/50) ≥ 0 °C (≥ 32 °F) p. 196) Outside Engine oil (SAE temperature: 5W/40) ( p.

  • Page 172: Adding Engine Oil

    SERVICE WORK ON THE ENGINE – Remove the screw plug and add the remaining engine oil to the upper marking  the engine oil level viewer. – Mount the screw plug. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
  • Page 173 Outside temperature: < 0 °C (< 32 °F) Engine oil (SAE 5W/40) ( p. 197) 500344-10 Info In order to achieve optimal engine performance, it is not advisable to mix differ- ent engine oils. KTM recommends changing the engine oil. – Mount the screw plug.
  • Page 174 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 175: Cleaning, Care

    CLEANING, CARE 20.1 Cleaning motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pres- sure can cause malfunctions or destroy these parts.
  • Page 176 CLEANING, CARE – 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 Reduced braking efficiency due to a wet or dirty brake sys- tem.

  • Page 177: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE Special cleaner for glossy and matte paint finishes, metal and plastic surfaces p. 200) – Oil the ignition/steering lock, tank lock, and seat lock. Universal oil spray ( p. 200) 20.2 Checks and maintenance steps for winter operation Info If you use the motorcycle in winter, you must expect salt on the roads.
  • Page 178 CLEANING, CARE – Clean the chain. ( p. 105)

  • Page 179: Storage

    Recharge the battery. p. 140) – Store the vehicle in a dry location that is not subject to large fluctuations in tempera- ture. Info KTM recommends jacking up the motorcycle. – Lift the motorcycle with the rear lifting gear. ( p. 97)

  • Page 180: Preparing For Use After Storage

    STORAGE – Lift the motorcycle with the front lifting gear. ( p. 98) – Cover the vehicle with a tarp or similar cover that is permeable to air. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.

  • Page 181: Troubleshooting

    140) – Check the open-circuit current. – The safety start system is faulty Read out the fault memory using the KTM diag- nostics tool. – CAN bus communication error Read out the fault memory using the KTM diag- nostics tool.
  • Page 182 Faults Possible cause Action – The engine turns but does not start Defect in the fuel injection system Read out the fault memory using the KTM diag- nostics tool. – The fuel quality is insufficient Add suitable fuel. – The engine dies during the trip Lack of fuel Refuel.

  • Page 183: Technical Data

    TECHNICAL DATA 23.1 Engine Design 2-cylinder 4-stroke Otto engine, 75° V arrangement, water-cooled Displacement 1,301 cm³ (79.39 cu in) Stroke 71 mm (2.8 in) Bore 108 mm (4.25 in) Compression ratio 13.2:1 Idle speed 1,300… 1,500 rpm Control DOHC, 4 valves per cylinder, chain-driven Valve - valve plate diameter Intake 42 mm (1.65 in)

  • Page 184: Engine Tightening Torques

    TECHNICAL DATA 1st gear 12:35 2nd gear 15:32 3rd gear 18:30 4th gear 20:27 5th gear 24:27 6th gear 27:26 Mixture preparation Electronically controlled fuel injection Ignition system Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 450 W Spark plug Inside spark plug NGK LKAR9BI9...
  • Page 185 TECHNICAL DATA – Screw, engine oil level viewer 4 Nm (3 lbf ft) Screw, gear sensor 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, pulse generator 6 Nm (4.4 lbf ft) Loctite ® 243™ – Bleeder screw, water pump cover 10 Nm (7.4 lbf ft) M6 –...
  • Page 186 TECHNICAL DATA Screw, water pump wheel 10 Nm (7.4 lbf ft) Loctite ® 243™ – Stud, chain shaft 8 Nm (5.9 lbf ft) Nozzle 100 M6x0.75 4 Nm (3 lbf ft) Loctite ® 243™ – Plug, crankshaft retainer 15 Nm (11.1 lbf ft) M8 –...

  • Page 187: Capacities

    TECHNICAL DATA – Screw, timing chain tensioner release M10x1 10 Nm (7.4 lbf ft) – Spark plug M10x1 11 Nm (8.1 lbf ft) Cylinder head screw M11x1.5 Tightening sequence: Lubricated with engine oil Using a crisscross pattern Step 1 15 Nm (11.1 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3...

  • Page 188: Coolant

    TECHNICAL DATA Engine oil 3.60 l (3.8 qt.) Outside temperature: < 0 °C Engine oil (SAE 5W/40) (< 32 °F) p. 197) 23.3.2 Coolant Coolant 3.20 l (3.38 qt.) Coolant ( p. 196) Coolant ( p. 196) 23.3.3 Fuel Total fuel tank capacity, approx. 18 l (4.8 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p.

  • Page 189: Electrical System

    TECHNICAL DATA Front 320 mm (12.6 in) Rear 240 mm (9.45 in) Brake discs - wear limit Front 4.5 mm (0.177 in) Rear 4.5 mm (0.177 in) Tire air pressure, solo/with passenger/full payload Front: with cold tires 2.5 bar (36 psi) Rear: with cold tires 2.9 bar (42 psi) Secondary drive ratio...

  • Page 190: Tires

    Rear tires 120/70 ZR 17 M/C 58W TL 190/55 ZR 17 M/C 75W TL Dunlop Sportmax Sportsmart² Dunlop Sportmax Sportsmart² Additional information is available in the Service section under: http://www.ktm.com 23.7 Fork Fork part number 14.18.8N.22 Fork WP Performance Systems 4860 ROTA SPLIT...

  • Page 191: Shock Absorber

    TECHNICAL DATA Sport 7 clicks Full payload 7 clicks Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks Spring length with preload spacer(s) 253 mm (9.96 in) Spring rate Medium (standard) 9.5 N/mm (54.2 lb/in) Fork length 776 mm (30.55 in) Air chamber length...
  • Page 192 TECHNICAL DATA Standard 1.5 turns Sport 1 turn Full payload 1 turn Rebound damping Comfort 15 clicks Standard 12 clicks Sport 9 clicks Full payload 9 clicks Spring preload Comfort 5 mm (0.2 in) Standard 5 mm (0.2 in) Sport 6 mm (0.24 in) Full payload 7 mm (0.28 in)

  • Page 193: Chassis Tightening Torques

    TECHNICAL DATA 23.9 Chassis tightening torques – Remaining screws, chassis EJOT PT ® K50x12 1 Nm (0.7 lbf ft) – Remaining screws, chassis EJOT PT ® K50x14 1 Nm (0.7 lbf ft) – Remaining screws, chassis EJOT PT ® K50x16 2 Nm (1.5 lbf ft) –...
  • Page 194 TECHNICAL DATA Screw, ball joint of push rod on foot 5 Nm (3.7 lbf ft) Loctite ® 243™ brake cylinder – Screw, battery terminal 4.5 Nm (3.32 lbf ft) Loctite ® 243™ Screw, clutch assembly 5 Nm (3.7 lbf ft) Screw, connecting piece, rear brake line 10 Nm (7.4 lbf ft) Loctite...
  • Page 195 TECHNICAL DATA – Nut, manifold on cylinder head Tightening sequence: Tighten the nuts evenly. Do not warp the metal plate. 25 Nm (18.4 lbf ft) – Nut, rear sprocket 36 Nm (26.6 lbf ft) – Nut, shift rod 12 Nm (8.9 lbf ft) –...
  • Page 196 TECHNICAL DATA Screw, steering damper on triple clamp 8 Nm (5.9 lbf ft) Loctite ® 243™ – Screw, top triple clamp 15 Nm (11.1 lbf ft) – Remaining nuts, chassis 45 Nm (33.2 lbf ft) – Remaining screws, chassis 45 Nm (33.2 lbf ft) Screw, engine bearer 45 Nm (33.2 lbf ft) Loctite...
  • Page 197 TECHNICAL DATA – Nut, steering head M28x1.0 Step 1 10 Nm (7.4 lbf ft) Step 2 (loosen, counterclock- wise) 60° Nut, rear axle, shock absorber side M35x1.5 200 Nm (147.5 lbf ft) Loctite ® 262™/lock the lock- ing wire with locking varnish Nut, rear axle M50x1.5 250 Nm (184.4 lbf ft)

  • Page 198: Substances

    SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®...
  • Page 199 SUBSTANCES Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Fully synthetic engine oil Recommended supplier Motorex ® – Power Synt 4T Engine oil (SAE 5W/40) Standard/classification –...
  • Page 200 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 201) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding proper- ties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification –...

  • Page 201: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Recommended supplier Motorex ® – Chain Clean Chain lube for road use Guideline Recommended supplier Motorex ® – Chainlube Road Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Long-life grease Recommended supplier Motorex ® – Bike Grease 2000 Motorcycle cleaner Recommended supplier...
  • Page 202 AUXILIARY SUBSTANCES Perfect Finish and high gloss polish for paints Recommended supplier Motorex ® – Moto Polish & Shine Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ®...

  • Page 203: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.

  • Page 204: Index Of Special Terms

    INDEX OF SPECIAL TERMS Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces Motorcycle Traction Control Auxiliary function of the motor control, which reduces engine torque with spinning rear wheel...

  • Page 205: List Of Abbreviations

    LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 206: Lisy Of Symbols

    LISY OF SYMBOLS 29.1 Red symbols Red symbols indicate an error condition that requires immediate intervention. The immobilizer indicator lamp lights up or flashes red – Status or error message for immobilizer/alarm system. The oil pressure warning lamp lights up red – Engine oil pressure is too low. 29.2 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention.
  • Page 207 LISY OF SYMBOLS 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 right turn signal lamp flashes green simultaneously with the turn signal – The right turn signal is switched on.

  • Page 208: Index

    INDEX INDEX Capacity ABS ........115 coolant .
  • Page 209 INDEX "Fuel Cons" ........61 "General Info" ....... . 54 Electric starter button .
  • Page 210 INDEX Front wheel Ignition lock ........37 installing .
  • Page 211 INDEX MTC ........163 Refueling fuel .
  • Page 212 INDEX Step plate of foot brake lever Troubleshooting ......179-180 setting ........67 Turn signal bulb Stopping .
  • Page 213 *3213400en* 3213400en 09/2015 KTM Sportmotorcycle GmbH Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com...

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