690 SMC - Supermoto motorcycle KTM - Free user manual and instructions

USER MANUAL 690 SMC KTM

Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly.

We wish you great pleasure riding the vehicle!

Enter the serial numbers of your vehicle below.

Chassis number (●P. 16)	Dealer's stamp
Engine number (●P. 17)
Key number (●P. 17)

The owner's manual corresponded to the latest state of this series at the time of printing. However, it is never possible to exclude small deviations arising from further development in design and construction.

All specifications are not binding. KTM Sportmotorcycle AG in particular 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 these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery.

© 2008 by KTM-Sportmotorcycle AG, Mattighofen Austria

All rights reserved

Reproduction, even in part, is permitted only with the express written permission of the copyright owner.

REG.NO.12 1006061

ISO 9001(12 100 6061)

Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM-Sportmotorcycle AG

5230 Mattighofen, Austria

MEANS OF REPRESENTATION 7

IMPORTANT NOTES 8

VIEW OF VEHICLE 12

View of vehicle, front left side 12

View of vehicle, rear right side 14

LOCATION OF SERIAL NUMBERS 16

Chassis number. 16

Type label. 16

Key number 17

Engine number. 17

Fork part number. 18

Shock absorber part number 18

OPERATING ELEMENTS 19

Clutch lever 19

Hand brake lever 19

Light switch 20

Light switch 20

Headlight flasher switch 21

Flasherswitch 21

Flasherswitch 22

Horn 22

Horn 23

Emergency OFF switch 23

Electric starter button 24

Ignition/steering lock 24

Combination instrument 25

Combination instrument - function buttons 25

Combination instrument - tachometer 26

Combination instrument - control lamps 26

Combination instrument - Display 27

Combination instrument - speed display 28

Setting kilometers or miles 28

Combination instrument - time 29

Setting the clock 29

Combination instrument - ODO display 30

Combination instrument - setting/resetting TRIP 1 display.... 30

Combination instrument - setting/resetting TRIP 2 display.... 31

Combination instrument - TRIP F display 32

Combination instrument - coolant temperature indicator ...... 32

Opening filler cap. 33

Closing filler cap 33

Handrails 34

Seat release 34

Passenger footrests 35

Shift lever 35

Foot brake pedal 36

Side stand 37

GENERAL TIPS AND HINTS ON PUTTING INTO

OPERATION 38

Advice on first use 38

Running in the engine. 40

Loading the vehicle 40

RIDINGINSTRUCTIONS 42

Checks before putting into operation 42

Starting 43

Starting up 45

Shifting, riding. 45

Braking 48

Stopping, parking 49

Refueling. 51

GREASING AND SERVICE TABLE 53

Important maintenance work to be carried out by an authorized KTM workshop. 53

Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) 55

MAINTENANCE WORK ON CHASSIS AND ENGINE 56

Jacking up the motorcycle 56

Removing the motorcycle from the work stand 56

Fork/shock absorber 57

Adjusting compression damping of fork 57

Adjusting rebound damping of fork 58

Compression damping of shock absorber. 59

Adjusting the low-speed compression damping of the shock absorber 59

Adjusting high-speed compression damping of the shock absorber 60

Adjusting rebound damping of the shock absorber 62

Bleeding fork legs 62

Cleaning dust boots of fork legs 63

Loosening the fork protection. 64

Positioning the fork protection 64

Checking play of steering head bearing 65

Adjusting play of steering head bearing 66

Adjusting the handlebar angle 67

Handlebar position 67

Adjusting handlebar position 68

Checking chain dirt 69

Cleaning the chain. 69

Checking the chain tension 70

Adjusting chain tension. 71

Checking rear sprocket / engine sprocket for wear 73

Checking chain wear. 74

Adjusting chain guide 75

Checking brake discs 75

Checking free play of hand brake lever. 76

Adjusting free travel of handbrake lever 77

Checking front brake fluid level. 78

Adding brake fluid for front brake 78

Brake linings. 80

Checking the front brake linings. 81

Changing the front brake linings 81

Checking free play of foot brake lever 85

Adjusting basic position of foot brake pedal 85

Checking rear brake fluid level 86

Topping up brake fluid of rear brake 87

Checking the rear brake linings 89

Changing rear brake linings 89

Removing front wheel 92

Fitting front wheel 94

Removing rear wheel 95

Fitting rear wheel 96

Checking the rear hub rubber dampers 97

Tire condition checking. 98

Checking tire air pressure 100

Checking spoke tension. 101

Removing the seat. 102

Mounting the seat 103

Removing the battery 103

Installing the battery 104

Recharging the battery 105

Changing the main fuse 107

Changingfuses of individual power consumers. 109

Adjusting the engine characteristic 111

Removing headlight mask with headlight 113

Refitting the headlight mask with the headlight 114

Changing the headlight bulb. 115

Changing the parking light bulb 116

Changing the flasher bulb 117

Checking headlamp setting. 118

Adjusting the headlight range 119

Removing the air filter 119

Installing the air filter 120

Cooling system 121

Checking the antifreeze and coolant level 122

Checking the coolant level 124

Draining coolant 126

Filling the cooling system 127

Adjusting basic position of clutch lever. 129

Checking/correcting fluid level of hydraulic clutch 129

Checking play in gas Bowden cable 130

Adjusting play in gas Bowden cable 131

Removing the engine guard 132

Installing the engine guard 132

Checking engine oil level 133

Changing engine oil and oil filter, cleaning oil

screens 133

Draining engine oil 134

Removing the oil filter 135

Mounting oil filter 137

Cleaning oil screens 137

Filling up with engine oil 139

Topping up engine oil 140

TROUBLESHOOTING 141

FLASHING CODE 144

CLEANING 147

Cleaning motorcycle 147

CONSERVATION FOR WINTER OPERATION 149

Conservation for winter operation 149

STORAGE 150

Storage 150

Putting into operation after storage 151

TECHNICAL DATA - ENGINE 152

Capacity - engine oil 153

Capacity - coolant. 153

TECHNICAL DATA - ENGINE TIGHTENING TORQUES. 154

TECHNICAL DATA - CHASSIS 157

Lighting equipment 158

Capacity - fuel. 159

TECHNICAL DATA - FORK. 160

TECHNICAL DATA - SHOCK ABSORBER 161

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 163

SUBSTANCES 166

AUXILIARY SUBSTANCES. 169

CONTENTS

STANDARDS. 171

INDEX 172

Symbols used

The symbols used are explained in the following.

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

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

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

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

Formats used

The typographical and other formats used are explained in the following.

Eigename

Indicates a proprietary name.

Name®

Identifies a protected name.

MarkeTM

Identifies a brand in merchandise traffic.

Use definition

KTM sport motorcycles are designed and constructed to meet the normal demands of regular road and light offroad operation (dirt roads), but not for use on race courses.

Info

The motorcycle is authorized for public road traffic in the homologous version only.

Maintenance

A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of components.

Using the motorcycle in extreme conditions such as very muddy or wet roads can lead to above-average wear of components such as the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the greasing and service table is reached.

Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle.

Warranty

The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.

Fuel, oils, etc.

You should use the fuels, oils and greases according to specifications as listed in the owner's manual.

Spare parts, accessories

For your own safety, use only spare parts and accessories approved by KTM, and have these mounted only in an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.

The current KTM PowerParts for your vehicle can be found on the KTM website.

International KTM Website: http://www.ktm.com

Transport

Note

Danger of damage Danger of damage by the vehicle running away or falling over.

Always place the vehicle on a firm and even surface.

Note

Fire hazard Some components (engine, radiator and exhaust system) get very hot when the engine is running.

• Do not place the vehicle where there are flammable or explosive substances.

• Switch off the engine and remove the ignition key.

• Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

Environment

Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.

Notes/warning notes

Pay attention to the specified notes and warnings.

Various notes and warning labels are attached to the vehicle. Do not remove any notes or warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured.

Grades of risks

Danger

Danger that leads immediately and certainly to severe and permanent injury or death.

Warning

Danger that will probably lead to severe and permanent injury or death.

Caution

Danger that could possibly lead to slight injuries.

Note

Danger of serious damage to machine or material.

Warning

Risk of environmental damage.

OWNER'S MANUAL

• Read this owner's manual carefully and completely before making your first trip. It contains a lot of information and tips to help you operate and handle your motorcycle. Only then will you find out how to customize the motorcycle ideally for your own use and how you can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.

The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.

View of vehicle, front left side

VIEW OF VEHICLE

1 Hand brake lever
2 Clutch lever
3 Handrail
4 Filler cap
5 Seat
6 Front brake caliper
7 Shift lever
8 Engine number
9 Side stand
10 Footrest
11 Seat release strap

View of vehicle, rear right side

VIEW OF VEHICLE

1	Ignition/steering lock
2	Rear mirror
3	Light switch, flasher switch, horn
4	Combination instrument
5	Emergency OFF switch, electric starter button
6	Throttle grip
7	Chassis number
8	Rear brake caliper
9	Passenger footrest
10	Shock absorber rebound damping
11	Foot brake pedal
12	Engine oil level viewer

Chassis number

The chassis number 1 is stamped on the steering head on the right.

Type label

Type label 1 is located on the upper right frame tube below the seat.

Key number

The key number ① can be found on the KEYCODECARD.

Info You

place.

Engine number

The engine number 1 is stamped on the left side of the engine under the engine sprocket.

Fork part number

The fork part number ① is stamped on the inner side of the fork stub.

Shock absorber part number

Shock absorber part number 1 can be viewed from the right side.

Clutch lever

The clutch lever 1 is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting.

Hand brake lever

The hand break lever 1 is fitted on the right side of the handlebar. The hand brake lever operates the front brake.

Light switch

The light switch 1 is fitted on the left side of the handlebar.

Possible states

Low beam on - Light switch is turned downwards. In this position, the low beam and tail light are switched on.

High beam on - Light switch is turned upwards. In this position, the high beam and the tail light are switched on.

Light switch

The light switch 1 is fitted on the left side of the handlebar.

Possible states

Low beam on - Light switch is turned downwards. In this position, the low beam and tail light are switched on.

High beam on - Light switch is turned upwards. In this position, the high beam and the tail light are switched on.

Headlight flasher switch

The headlight flasher switch ① is fitted on the left side of the handlebar.

Possible states

• Headlight flasher switch in neutral position
• Headlight flasher switch pressed - In this position, the headlight flasher (high beam) is actuated.

Flasher switch

The flasher switch 1 is fitted on the left side of the handlebar.

Possible states

Flasher light off Flasher light, left, on - Flasher switch pressed to the right. The flasher switch returns automatically to the central position after use.
Flasher light, right, on - Flasher switch pressed to the right. The flasher switch returns automatically to the central position after use.

To switch off the flasher light, press the flasher switch towards the switch case.

Flasher switch

The flasher switch is fitted on the left side of the handlebar.

Possible states

Flasher light off Flasher light, left, on - Flasher switch pressed to the right. The flasher switch returns automatically to the central position after use.
Flasher light, right, on - Flasher switch pressed to the right. The flasher switch returns automatically to the central position after use.

To switch off the flasher light, press the flasher switch towards the switch case.

Horn

The horn button 1 is fitted on the left side of the handlebar.

Possible states

• Horn button in neutral position
• Horn button pressed - The horn is operated in this position.

Horn

The horn button 1 is fitted on the left side of the handlebar.

Possible states

• Horn button in neutral position
• Horn button pressed - The horn is operated in this position.

Emergency OFF switch

The emergency OFF switch 1 is fitted on the left side of the handlebar.

Possible states

Emergency OFF switch off - In this position, the ignition circuit is interrupted, a running engine stops, and the engine cannot be started.

Emergency OFF switch on - This position is necessary for operation as the ignition circuit is closed.

Electric starter button

The electric starter button 1 is fitted on the right side of the handlebar.

Possible states

Electric starter button in basic position
Electric starter button pressed - In this position, the electric starter is actuated.

Ignition/steering lock

The ignition/steering lock 1 is located in front of the seat.

Possible states

Ignition 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 - In this position, the ignition circuit is closed, and the engine can be started.

Steering locked - In this position, the ignition circuit is interrupted and the steering locked. The ignition key can be removed.

Combination instrument

The combination instrument is attached in front of the handlebar.

The combination instrument is divided into 4 function areas.

Function buttons
Tachometer
Indicator lights
4 Display

Combination instrument - function buttons

Press the MODE button to change the display mode.

Possible display modes are total distance covered (ODO), tripmaster 1 (TRIP 1) and tripmaster 2 (TRIP 2).

Press the SET button 2 to reset tripmaster 1 (TRIP 1) and tripmaster 2 (TRIP 2) to 0.0.

Button ③ has no function.

Combination instrument - tachometer

The tachometer ① displays the engine speed in revolutions per minute. The red marking ② shows the excess engine speed range.

Combination instrument - control lamps

The indicator lamps provide additional information on the operating state of the motorcycle.

Possible states

Flashing indicator flashes green in flash rhythm - Flasher light is switched on.

Idling speed indicator lamp lights up green - Transmission is in neutral.

High beam indicator lamp lights up blue - High beam is switched on.

Temperature warning lamp lights up red - Coolant has reached a critical value.

Fuel level warning lamp lights up orange - Fuel level has reached the reserve mark. Display switches to TRIP F.

FI warning lamp (MIL) lights/flashes orange - The OBD has detected an emission- or safety-critical error.

Battery warning lamp lights up - Voltage in electrical system too low.

Combination instrument - Display

When you switch on the ignition, all display segments light up for a second as a function test.

LEnGTth

Following the display function test, the wheel circumference LEnGth is shown for one second.

Info

2205 mm equals the circumference of the 21" front wheel with a series production tire.

The display then changes to the last selected mode.

Combination instrument - speed display

The speed is displayed in kilometers per hour km/h or miles per hour Mph.

Setting kilometers or miles

Info

If you change the unit, the ODO value is retained and converted accordingly. Making the setting according to the country.

Condition

The motorcycle is standing.

• Switch on the ignition by turning the ignition key in the position .
• Press the MODE button several times until the ODO display mode is active.
• Keep the MODE button pressed until the display mode changes from Km/h to Mph or from Mph to Km/h.

Specification

Activation duration of MODE button

10s

Combination instrument - time

The time is shown in area 1 of the display.

The time must be adjusted after the battery is disconnected or the fuse is changed.

Setting the clock

Condition

The motorcycle is standing.

• Switch on the ignition by turning the ignition key in the position .
• Press the MODE button several times until the ODO display mode is active.
• Keep the MODE button and the SET button pressed simultaneously.

The time begins to flash.

• Press the MODE button to adjust the hour.
• Press the SET button to adjust the minute.
• Keep the MODE button and the SET button pressed simultaneously.

The time is set.

Combination instrument - ODO display

In ODO mode, the total distance covered is shown in kilometers or miles.

This value remains intact even if the battery is disconnected and/or the fuse blows.

Combination instrument - setting/resetting TRIP 1 display

Info

The tripmaster TRIP 1 operates constantly and counts up to 999.9.

You can use the tripmaster to measure trips or the distance between refuelling stops. After reaching 999.9, the tripmaster begins again at 0.0.

• Switch on the ignition by turning the ignition key in the position .
• Press the MODE button several times until the TRIP 1 display mode is active.
• Keep the SET button pressed.

The TRIP 1 display is at 0.0.

Combination instrument - setting/resetting TRIP 2 display

Info

The tripmaster TRIP 2 operates constantly and counts up to 999.9.

You can use the tripmaster to measure trips or the distance between refuelling stops. After reaching 999.9, the tripmaster begins again at 0.0.

• Switch on the ignition by turning the ignition key in the position .
• Press the MODE button several times until the TRIP 2 display mode is active.
• Keep the SET button pressed.

The TRIP 2 display is at 0.0.

Combination instrument - TRIP F display

When the fuel level reaches the reserve mark, the display automatically changes to TRIP F and begins to count from 0.0, regardless of which display mode was previously active.

Info Parallel to the TRIP F display, the fuel warning light begins to light up.

Combination instrument - coolant temperature indicator

The temperature indicator in the display consists of 12 bars. The more bars that light up, the hotter the coolant. When the top bar lights up, all bars begin to flash simultaneously and the temperature warning lamp begins to light up.

Possible states

• Engine cold - up to four bars light up.
• Engine at normal operating temperature – from five to eleven bars light up.
• Engine hot - all twelve bars flash.

Opening filler cap

• Lift the cover of the filler cap 1 and insert the ignition key.
• Turn the ignition key 90^ counterclockwise and remove the filler cap.

The filler cap has a tank air vent system.

Closing filler cap

Put the filler cap back on and turn the ignition key 90^ clockwise.
- Remove the ignition key and fold down the cover.

Handrails

The handrails are used for moving the motorcycle around.

When you have a passenger, the passenger can hold on the handrails during the journey.

Seat release

The seat can be released using strap 1.

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.

Shift lever

The shift lever 1 is mounted on the left side of the engine.

The gear positions can be seen in the photograph.

The neutral or idle position is between the first and second gears.

Foot brake pedal

The footbrake pedal is located in front of the right footrest.

The footbrake pedal operates the rear brake.

Side stand

The side stand ① is coupled with the safety electric starter system - see the riding instructions.

Possible states

• Side stand folded out - The vehicle can be supported on the side stand. The safety electric starter system is active.
• Side stand folded in – This position is mandatory for all journeys. The safety electric starter system is inactive.

Advice on first use

Danger

Danger of accidents Danger from inadequate traffic experience.

• Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs.

Warning

Risk of injury Risk of injury by missing/inadequate protective clothing.

• Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the motorcycle. Always wear protective clothing, which must be in perfect condition and meet legal requirements.

Warning

Danger of crashing Impairment of riding behavior due to different tire tread patterns on front and rear wheels.

The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.

Warning

Danger of accidents Uncontrollable handling behavior caused by non-approved tires/wheels.

• Use only tires/wheels approved by KTM with the corresponding speed index.

Warning

Danger of accidents Reduced road grip with new tires.

• New tires have a smooth roll surface and therefore cannot provide full road grip. The entire roll surface must be roughened in the first 200 kilometers (124.3 miles) by moderate driving at alternating angles. The full grip is not reached until the vehicle has been run in.

Warning

Danger of accidents Brake system failure.

If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take your foot off the foot brake pedal if you do not want to brake.

Info

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 record at vehicle handover.
  Before your first trip, read the entire operating instructions carefully.
  Get to know the operating elements.
• adjust the basic position of clutch lever. (P. 129)
• Adjust the free travel of the handbrake lever. (P. 77)
• Adjust the basic position of the foot brake pedal. (P. 85)
  Get used to handling the vehicle on a car park before making a longer trip. Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.
• Do not make any offroad trips that over-stress your ability and experience.
  Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
• Do not make any changes to the vehicle, and use only KTM approved parts.

Info

Parts from other manufacturers can reduce the operational safety of the vehicle.

Run the engine in.

Running in the engine

• During the running-in phase, do not exceed the specified engine speed and engine performance.

Specification

Maximum engine speed
During the first: 1,000 km (621.4 mi)	6,000 rpm
After the first: 1,000 km (621.4 mi)	7,800 rpm

• Avoid fully opening the throttle!

Loading the vehicle

Warning

Danger of accidents Unstable riding behavior.

• 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.

Warning

Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack.

• Mount and secure suitcase and tank rucksack according to the manufacturer's instructions.

Warning

Danger of accidents Unstable handling characteristics at high speed.

• Adapt your speed according to your payload. Ride more slowly if your motorcycle is loaded with cases or other baggage. Maximum speed with baggage 130 km/h (80.8 mph)

Warning

Danger of accidents Risk of breakage of suitcase system.

If you have fitted suitcases on your motorcycle, read the manufacturer's specifications concerning the maximum payload.

Warning

Danger of accidents Poor visibility for other road users due to slipped baggage.

If the tail light is covered, you are less visible to following traffic, especially in the dark. Check the way your baggage is fixed regularly.

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.

• Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system.

If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels.
- Do not exceed the overall maximum permitted weight and the axle loads.

Specification

Maximum permissible overall weight	350 kg (772 lb.)
Maximum permissible front axle load	150 kg (331 lb.)
Maximum permissible rear axle load	200 kg (441 lb.)

Checks before putting into operation

Info

Make sure that the motorcycle is in a perfect technical condition before use.

In the interests of riding safety, make a habit of making a general check before you ride.

• Check the engine oil level. (P. 133)
• Check the engine for loss of oil.
• Check the fuel level.
• Bleed fork legs. (P. 62)

Specification

all

1,000 km (621.4 mi)

• Check the chain tension. (P. 70)
  Clean the chain. (P. 69)
• Check the tire condition. (P. 98)
• Checking the tire air pressure. (P. 100)
• Check the front brake brake fluid level. (P. 78)
• Check the rear brake fluid level. (P. 86)
• Check the front brake linings. (P. 81)
• Check the rear brake linings. (P. 89)
• Check brake system function.
• Check the coolant level. (P. 124)
• Check that all operating elements are correctly adjusted and free to move.
• Check the functioning of the electrical equipment.
• Check that baggage is correctly secured.
  Sit on the motorcycle and check the rear mirror setting.

Starting

Danger

Danger of poisoning Exhaust gases are poisonous and can 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 a closed space.

Caution

Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety equipment may be damaged.

• Never operate the vehicle with a discharged battery or without a battery.

Note

Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.

Always warm up the engine at low engine speeds.

• Turn the emergency OFF switch to the position .
• Switch on the ignition by turning the ignition key in the position .

✓ After switching on the ignition, you can hear the fuel pump working for about 2 seconds. At the same time, the combination instrument runs a function test.

• Shift gear to neutral.
  The green idling speed indicator lamp N lights up.
• Press the electric starter button (3).

Info Do r

Do not press the electric starter button until the combination instrument function test is finished.

Do not open the throttle when starting. If you open the throttle when starting, the engine management injects no fuel and the engine cannot start.

Press the starter for a maximum of 5 seconds. Wait for at least 5 seconds until trying again.

This motorcycle is equipped with a safety electric starter system. The engine can be started only if the gearbox is in neutral or the clutch lever is pulled. If you shift into gear when the side stand is folded out and then release the clutch lever, the engine stalls.

Take the weight off the side stand and swing it back up with your foot as far as it will go.

Starting up

Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.

Shifting, riding

Warning

Danger of accidents An abrupt load alterations can cause the vehicle to get out of control.

• Avoid abrupt load alterations and sudden braking actions, and adapt your speed to the road conditions.

Warning

Danger of accidents If you change down at high engine speed, the rear wheel can lock up.

• Do not change into a low gear at high engine speed. The engine races and the rear wheel can block.

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 The passenger must be capable of sitting correctly on the passenger seat.

• The passenger must hold on to the rider or the handrails and place his feet on the passenger footrests. Note the regulations governing the minimum age of passengers in your country.

Warning

Danger of accidents Danger of accidents caused by dangerous driving.

• Observe the traffic regulations and ride defensively and with foresight in order to recognize danger as early as possible.

Warning

Danger of accidents Reduced road grip with cold tires.

• On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured.

Warning

Danger of accidents Reduced road grip with new tires.

• New tires have a smooth roll surface and therefore cannot provide full road grip. The entire roll surface must be roughened in the first 200 kilometers (124.3 miles) by moderate driving at alternating angles. The full grip is not reached until the vehicle has been run in.

Warning

Danger of accidents Unstable riding behavior.

• 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.

Warning

Danger of accidents Unstable handling characteristics due to slipped baggage.

• Check the way your baggage is fixed regularly.

Warning

Danger of accidents After a fall, check the vehicle.

After a fall, check the vehicle as usual before putting it into operation.

Note

Engine failure Unfiltered intake air has a negative effect on the service life of the engine.

• Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.

Note

Engine failure Overheating of engine.

• If the coolant temperature warning lamp lights up, stop and switch off the engine. Allow the engine to cool down and check the coolant level in the radiator, and top up if necessary. 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.

• When conditions allow (incline, road situation, etc.), you can shift into a higher gear.
• Release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.

For the positions of the 6 forward gears, see the illustration. The neutral or idle position is between the first and second gears. First gear is used for starting off or for steep inclines.

The operating temperature is reached when 5 bars of the temperature indicator light up.

• When you reach maximum speed after fully opening the throttle, turn back the throttle to about 34 of its range; the speed hardly drops, but the fuel consumption falls considerably.
• Open the throttle only as far as the road and weather conditions permit. Particularly in bends, do not shift and open the throttle only very cautiously.
• To shift down, brake if necessary and close the throttle at the same time.

• Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again.

• For example, if the engine stalls at a junction, just pull the clutch and press the electric starter button. You do not need to shift into neutral.

• Switch off the engine if you expect to be standing for a long time.
• Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and the cooling system.
• Ride with a lower engine speed instead of with a high engine speed and a slipping clutch.
• If the FI warning lamp (MIL) starts to light up during the journey, stop immediately. If you shift to neutral, the FI warning lamp (MIL) begins to flash.

From the flash rhythm, you can deduce a two-digit number, the so-called flash code. The flash code tells you which component is affected by a fault.

Braking

Warning

Danger of accidents If you brake too hard, the wheels can lock.

• Adapt your braking to the traffic situation and the road conditions.

Warning

Danger of accidents Reduced braking due to wet or dirty brakes.

• Clean or dry dirty or wet brakes by riding and braking gently.

Warning

Danger of accidents Reduced braking caused by spongy pressure point of front or rear brake.

• Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Danger of accidents Brake system failure.

If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take your foot off the foot brake pedal if you do not want to brake.

Warning

Danger of accidents Longer stopping distance due to higher overall weight.

Take the longer stopping distance into account when carrying a passenger and baggage.

Warning

Danger of accidents Delayed brake action on salted roads.

Salt can be deposited on the brake discs. To achieve the normal braking effect, the brake discs must first be cleaned by braking.

• To brake, release the throttle and operate the front and rear brakes simultaneously.
• On sandy, wet or slippery surfaces, use the rear brake.
• Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
• On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overpress the engine. In this way, you have to brake far less and the brakes do not overheat.

Stopping, parking

Warning

Risk of misappropriation Usage by unauthorized persons.

• Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. If you leave the vehicle, lock the steering and remove the ignition key.

Warning

Danger of burns Some vehicle components get very hot when the machine is driven.

• Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these components to cool down before starting work on them.

Note

Danger of damage Danger of damage by the vehicle running away or falling over.

Always place the vehicle on a firm and even surface.

Note

Fire hazard Some components (engine, radiator and exhaust system) get very hot when the engine is running.

• Do not place the vehicle where there are flammable or explosive substances.

Note

Material damage Damage and destruction of components by excessive load.

• The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over.

• Brake the motorcycle.

• Shift gear to neutral.
• Switch off the ignition by turning the ignition key in the position

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 and the battery will discharge. You should therefore always switch off the engine with the ignition key - the emergency OFF switch is intended for emergencies only.

• Park the motorcycle on a hard surface.

• Swing the side stand forward with your foot as far as it will go and lean the vehicle on it.

• Lock the steering by moving the handlebar to the left, pressing down the ignition key in the position and turning it to the position . To make locking the steering easier, move the handlebar a little to the left and right. Remove the ignition key.

Refueling

Danger

Fire hazard Fuel can easily catch fire.

• Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
  Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

• Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel.

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.

Info

This motorcycle is equipped with a regulated catalyst. Leaded fuel will destroy the catalyst. You should therefore use unleaded fuel only.

• switch off engine.
• Open the filler cap. (P. 33)
• Fill the fuel tank with fuel up to measurement A.

Specification

Measurement of θ		20 mm (0.79 in)
Fuel tank content	12 l (3.2 US gal)	Super unleaded (ROZ 95 / RON 95 / PON 91) (P. 168)

• Close the filler cap. (P. 33)

• Press the SET ② function button for 2 seconds.

• The fuel level warning lamp ① switches off. TRIP F is set to 0 and appears in the previous display mode.

If you do not press the SET ② function button, the reset takes place automatically after about 3 minutes.

Important maintenance work to be carried out by an authorized KTM workshop.

		K10N	K50A	K100A	J1A	J2A
Engine	Change engine oil and oil filter, clean oil screens. (P. 133)	●	●	●	●	●
	Check and adjust valve clearance.			●		●
	Check engine mounting screws for tightness.	●	●	●	●	●
	Replace spark plug.			●
	Check engine bolts accessible from outside for tightness.	●	●	●	●	●
Fuel injection	Check connection boots for cracks and leakage.	●		●		●
	Read out the error memory with a KTM diagnostic tool.	●	●	●	●	●
	Check fuel hoses, SLS hoses and vent hoses for damage, correct fitting and leaks.	●	●	●	●	●
	Clean, check and grease the O-ring of the fuel hose connection.		●	●	●	●
	Check the cable harness of the throttle valve body for damage and correct positioning.	●		●		●
Attachments	Check the cooling system for leakage.	●	●	●	●	●
	Check the antifreeze and coolant level. (P. 122)	●	●	●	●	●
	Check the functioning of the radiator fan.	●	●	●	●	●
	Check the exhaust system for leaks and correct fitting and check that the exhaust holders are tight.	●	●	●	●	●
	Check Bowden cables for damage, smooth operation, routing without sharp bends and setting.	●	●	●	●	●
	Check/correct the fluid level of the hydraulic clutch. (P. 129)		●	●	●	●
	Check air filter and change if necessary. Clean the air filter box.		●	●	●	●
	Check cables for damage and routing without sharp bends.	●	●	●	●	●
	Check the headlamp setting. (P. 118)	●	●	●	●	●

GREASING AND SERVICE TABLE

		K10N	K50A	K100A	J1A	J2A
Attachments	Check the functioning of the electrical equipment.	●	●	●	●	●
	Check screws and nuts for tightness.	●	●	●	●	●
Brakes	Check the front brake linings. (▼ P. 81)	●	●	●	●	●
	Check the rear brake linings. (▼ P. 89)	●	●	●	●	●
	Check the brake discs. (▼ P. 75)	●	●	●	●	●
	Check the front brake brake fluid level. (▼ P. 78)	●	●	●	●	●
	Check the rear brake fluid level. (▼ P. 86)	●	●	●	●	●
	Change brake fluid.	●	●	●	●	●
	Check brake lines for damage and leakage.	●	●	●	●	●
	Check the free play of the foot brake lever. (▼ P. 85)	●	●	●	●	●
	Check braking.	●	●	●	●	●
	Check screws and guide bolts of brake system for tightness.	●	●	●	●	●
Chassis	Check shock absorber and fork for leakage and functioning.	●	●	●	●	●
	Clean dust boots of fork legs.	●	●	●	●	●
	Bleed fork legs. (▼ P. 62)	●	●	●	●	●
	Check swingarm bearing.	●	●	●	●	●
	Check play of steering head bearing. (▼ P. 65)	●	●	●	●	●
	Check all screws to see if they are tight.	●	●	●	●	●
	Grease Pro-Lever deflector.	●	●	●	●	●
Wheels	Check the spoke tension. (▼ P. 101)	●	●	●	●	●
	Check rim run-out.	●	●	●	●	●
	Check the tire condition. (▼ P. 98)	●	●	●	●	●
	Checking the tire air pressure. (▼ P. 100)	●	●	●	●	●
Wheels	Check the chain wear. (P. 74)	●	●	●	●	●
	Check rear sprocket / engine sprocket for tightness.	●	●	●	●	●
	Check rear sprocket / engine sprocket for wear. (P. 73)	●	●	●	●	●
	Check the chain tension. (P. 70)	●	●	●	●	●
	Clean the chain. (P. 69)	●	●	●	●	●
	Check wheel bearing for play.		●	●	●	●
	Checking the rear hub rubber dampers. (P. 97)		●	●	●	●

K10N: after 1,000 km (621.4 mi)
K50A: every 5,000 km (3,107 mi) / after every race
K100A: every 10,000 km (6,214 mi)
J1A: annually
J2A: every 2 years

Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)

	K100A	J1A	J2A
Carry out a complete fork service.	●		●
Carry out a complete shock absorber service.	●		●
Clean and grease steering head bearing and sealing elements.			●
Treat electric contacts with contact spray.		●	●
Clean the battery terminals and treat them with contact grease.		●	●
Change coolant.			●

K100A: every 10,000 km (6,214 mi)
J1A: annually
J2A: every 2 years

Jacking up the motorcycle

Note

Danger of damage Danger of damage by the vehicle running away or falling over.

Always place the vehicle on a firm and even surface.

• Jack up the motorcycle on the underride guard underneath the engine. The wheels must no longer touch the ground.
• Secure the motorcycle against falling over.

Removing the motorcycle from the work stand

Note

Danger of damage Danger of damage by the vehicle running away or falling over.

Always place the vehicle on a firm and even surface.

• Remove the motorcycle from the work stand and rest it on its side stand.
• Remove the work stand.

Fork/shock absorber

The fork and the shock absorber offer many options of adapting the chassis to your riding style and the payload.

Info To help you adapt the vehicle, we have summarized our findings in Table 1. You can find the table on the underside of the seat.

These adjustments should be understood as a guideline and should always be the basis of your own personal chassis adaptation. Do not change the adjustments at random or by more than ± 40% , since otherwise the riding characteristics could deteriorate, particularly at high speeds.

Adjusting compression damping of fork

Info

The hydraulic compression damping determines the fork suspension behavior.

• Remove protection covers 1.
  Turn adjusting screws ② clockwise until they stop.

The adjusting screws are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.

• Turn back counterclockwise the number of clicks corresponding to the fork type. Specification

Compression damping
Comfort	20 clicks
Standard	15 clicks
Sport	10 clicks
full payload	10 clicks

Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

• Mount protection covers 1.

Adjusting rebound damping of fork

Info

The hydraulic rebound damping determines the fork suspension behavior.

Turn adjusting screws 1 clockwise until they stop.

Info The adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs.

• Turn back counterclockwise the number of clicks corresponding to the fork type. Specification

Rebound damping
Comfort	20 clicks
Standard	15 clicks
Sport	10 clicks
full payload	10 clicks

Info

Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

Compression damping of shock absorber

The shock absorber can regulate compression damping in low- and high-speed range separately (Dual Compression Control). The term low and high speed refers to the movement of the shock absorber during compression and not the riding speed of the motorcycle. The low- and high-speed technology works non-specifically.

Adjusting the low-speed compression damping of the shock absorber

Danger

Danger of accidents The shock absorber is under high pressure.

The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any maintenance on it yourself.

Info

The low-speed setting can be seen during the slow to normal compression of the shock absorber.

• Turn the adjusting screw ① clockwise with a screwdriver until it stops.

Do not loosen nut 2!

• Turn back counterclockwise the number of clicks corresponding to the shock absorber type.

Specification

Compression damping, low-speed
Comfort	20 clicks
Standard	15 clicks
Sport	10 clicks
full payload	10 clicks

Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

Adjusting high-speed compression damping of the shock absorber

Danger

Danger of accidents The shock absorber is under high pressure.

The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any maintenance on it yourself.

Info

The high-speed setting can be seen during the fast compression of the shock absorber.

• Turn the adjusting screw ① clockwise with an open-ended spanner until it stops.

Info Do not loosen nut 2!

• Turn back counterclockwise the number of turns corresponding to the shock absorber type.

Specification

Compression damping, high-speed
Comfort	2 turns
Standard	1.5 turns
Sport	1 turn
full payload	1 turn

Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

Adjusting rebound damping of the shock absorber

Danger

Danger of accidents The shock absorber is under high pressure.

The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any maintenance on it yourself.

Turn the adjusting screw ① clockwise until it stops.
- Turn back counterclockwise the number of clicks corresponding to the shock absorber type.

Specification

Rebound damping
Comfort	20 clicks
Standard	15 clicks
Sport	10 clicks
full payload	10 clicks

Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

Bleeding fork legs

• Lean the motorcycle on the side stand.

• Remove bleeder screws ① briefly.

Any excess pressure escapes from the interior of the fork.

Mount and tighten bleeder screws.

Carry out this action on both fork legs.

Cleaning dust boots of fork legs

• Jack up the motorcycle. (P. 56)
• Loosen the fork protection. (P. 64)
  Push dust boots ① of both fork legs downwards.

The dust boots should remove dust and coarse dirt particles from the fork tubes.

Over time, dirt can penetrate behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak.

Danger of accidents Reduced braking 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.

• Clean and oil the dust boots and inner fork tube of both fork legs.

Universal oil spray (P. 170)

• Press the dust boots back into their normal position.

• Remove excess oil.

• Position the fork protection. (P. 64)
• Remove the motorcycle from the work stand. (P. 56)

Loosening the fork protection

• Remove screws and take off clamp.
• Remove screws ② on left fork leg. Push the fork protection downwards.
• Remove the screws on the right fork leg. Push the fork protection downwards.

Positioning the fork protection

Position the fork protection on the left fork leg. Mount and tighten screws 1.

Specification

Remaining screws, chassis

M6

10 Nm (7.4 lbf ft)

• Position the brake line and cable harness. Put the clamp on, mount and tighten screws ②.
  Position the fork protection on the right fork leg. Mount and tighten screws. Specification

Remaining screws, chassis

M6

10 Nm (7.4 lbf ft)

Checking play of steering head bearing

Warning

Danger of accidents Unsafe riding behavior due to incorrect steering head bearing play.

• The steering head bearing play should be adjusted immediately in an authorized KTM workshop.

Info

If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time.

• Jack up the motorcycle. (P. 56)
• Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel.

No play should be noticeable in the steering head bearing.

If there is noticeable play present:

• Adjust play of the steering head bearing. (P. 66)

• Move the handlebar to and fro over the entire steering range.

The handlebar must be able to move easily over the entire steering range. No resting locations should be noticeable.

If click positions are noticeable:
- Adjust play of the steering head bearing. (P. 66)
- Check the steering head bearing and change if necessary.

• Remove the motorcycle from the work stand. (P. 56)

Adjusting play of steering head bearing

• Jack up the motorcycle. (P. 56)
• Loosen screw ①. Remove screw ②.
• Loosen and retighten screw ③.

Specification

Screw, top steering head

M20x1.5

10 Nm (7.4 lbf ft)

Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
- Fully tighten screw 1.

Specification

Screw, top triple clamp

M8

17 Nm (12.5 lbf ft)

Mount and tighten screw ②.

Specification

Screw, steering stem

M8

20 Nm (14.8 lbf ft)

Loctite® 243TM

• Check play of steering head bearing. (P. 65)
• Remove the motorcycle from the work stand. (P. 56)

Adjusting the handlebar angle

• Loosen screw 1.
• Move the handlebar to the desired position and slightly tichen the screws.
• Move the handlebar carefully in both directions as far as it will go.

If the handlebar instruments touch the fuel tank:

• Correct the handlebar angle.

I Info The distance between the handlebar support and the handlebar clamp must be the same at the front and rear.

• Fully tighten screw 1.

Specification

Screw, handlebar clamp

M8

20 Nm (14.8 lbf ft)

Loctite® 243TM

Handlebar position

On the upper triple clamp, there are 2 holes at a distance ±b to each other.

Distance A between holes

15 mm (0.59 in)

The holes on the handlebar support are placed at a distance 3 from the center.

Distance B between holes

3.5 mm (0.138 in)

The handlebar can be mounted in 4 different positions. In this way, the handlebar can be installed in the position most comfortable for the rider.

Adjusting handlebar position

• Remove the four screws . Remove the handlebar clamp. Remove the handlebar and lay it to one side.

Info

Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines.

• Remove the two screws ② . Remove the handlebar support.
• Place the handlebar support in the required position. Fit and tighten the two screws ② . Specification

Screw, handlebar support

M10

40 Nm (29.5 lbf ft)

Info Posi

Position the left and right handlebar supports evenly.

Position the handlebar.

Info

Info Make sure cables and wiring are positioned correctly.

Position the handlebar clamp. Fit and evenly tighten the four screws 1.

Specification

Screw, handlebar clamp

M8

20 Nm (14.8 lbf ft)

Loctite® 243™

Checking chain dirt

• Check the chain for coarse dirt accumulation.

If the chain is very dirty:

Clean the chain. (P. 69)

Cleaning the chain

Warning

Danger of accidents Oil or grease on the tires reduces their grip.

• Remove oil and grease with a suitable cleaning material.

Warning

Danger of accidents Reduced braking 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 Problem materials cause environmental damage.

• Dispos of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

The service life of the chain depends largely on its maintenance.

Clean the chain regularly.
Rinse off loose dirt with a soft jet of water.
- Remove old grease remains with chain cleaner.

Chain cleaner (P. 169)

MAINTENANCE WORK ON CHASSIS AND ENGINE

After drying, apply chain spray.

Offroad chain spray (P. 170)

Checking the chain tension

Warning

Danger of accidents Danger caused by incorrect chain tension.

• If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaf of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary.

• Lean the motorcycle on the side stand.
• Shift gear to neutral.
• Push the chain upward at a distance from the chain sliding guard and determine the chain tension A .

Info The

The upper chain section must be taut.

Chain wear is not always even, so you should repeat this measurement at different chain positions.

Chain tension	5 mm (0.2 in)
Distance to chain sliding guard	30 mm (1.18 in)

If the chain tension does not meet specifications:

• Adjust the chain tension. (P. 71)

Adjusting chain tension

Warning

Danger of accidents Danger caused by incorrect chain tension.

• If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaf of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary.

MAINTENANCE WORK ON CHASSIS AND ENGINE

• Lean the motorcycle on the side stand.
• Shift gear to neutral.
• Loosen nut 1.
• Loosen nuts ②.
• Adjust the chain tension by turning the adjusting screws ③ left and right. Specification

Chain tension	5 mm (0.2 in)
Turn the adjusting screws ③ left and right so that the markings on the left and right chain adjusters ④ are in the same position relative to the reference marks ⑧. The rear wheel is then correctly aligned.

Info The upper chain section must be taut.

Chain wear is not always even, so you should repeat this measurement at different chain positions.

• Tighten nuts ②.
• Make sure that the chain adjusters 4 are fitted correctly on the adjusting screws 3.
• Tighten nut 1.

Specification

Nut, rear wheel spindle

M25x1.5

90 Nm (66.4 lbf ft)

Info
The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length.
The chain adjusters 4 can be turned by 180^

Checking rear sprocket / engine sprocket for wear

• Check rear sprocket / engine sprocket for wear.

If the rear sprocket / engine sprocket are worn:

• Replace rear sprocket / engine sprocket.

I Info The engine sprocket, rear sprocket and chain should always be replaced together. For safety reasons, the chain has no chain joint. Always have the chain replaced in an authorized KTM workshop, where the necessary chain rivet tool is available.

• Check chain guides for tightness and wear.

Checking chain wear

• Shift into neutral, pull the lower chain section with the specified weight A . Specification

Weight of chain wear measurement

15 kg (33 lb.)

• Measure the distance b of 18 chain links in the lower chain section.

Info

Info
Chain wear is not always even, so you should repeat this measurement at different chain positions.

Maximum distance 3 at the longest chain section

272 mm (10.71 in)

If the distance is greater than the specified measurement: Have the chain changed.

Inf Wh

When the chain is replaced, the rear sprocket and engine sprocket should also be changed.
New chains wear out faster on old, worn sprockets.
For safety reasons, the chain has no chain joint. Always have the c changed in an authorized KTM workshop, where the necessary tool available.

Adjusting chain guide

• Remove screws ① and ②. Take off the chain guide.

Conditions

Number of teeth: ≤ 44 teeth

• Insert nut ③ in hole A. Position the chain guide.
• Mount and tighten screws ① and ②.

Specification

Remaining screws, chassis

M6

10 Nm (7.4 lbf ft)

Conditions

Number of teeth: ≥ 45 teeth

• Insert nut ③ in hole ⑤. Position the chain guide.
  Mount and tighten screws 1 and 2.

Specification

Remaining screws, chassis

M6

10 Nm (7.4 lbf ft)

Checking brake discs

Warning

Danger of accidents Reduced braking due to worn brake discs.

• Worn brake discs should be replaced immediately in an authorized KTM workshop.

• Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement A.

Info

Wear reduces the thickness of the brake disc around the area used by the brake linings.

Wear limit of brake discs
front	4.5 mm (0.177 in)
Rear	3.5 mm (0.138 in)

If the brake disc thickness is less than the specified value:

• Change the brake disc.

Checking free play of hand brake lever

Warning

Danger of accidents Brake system failure.

• If there is no free travel on the hand brake lever, pressure builds up on the front brake in the brake system. The front brake can fail due to overheating. Adjust free travel on hand brake lever according to specifications.

Push the hand brake to the handlebar and check free play A.

Free play of hand brake lever

≥ 3 ~mm (≥ 0.12 in)

If the free travel does not meet specifications:

• Adjust the free travel of the handbrake lever. (P. 77)

Adjusting free travel of handbrake lever

• Adjust the free travel of the handbrake lever with the adjustment screw ①.

Turn the adjustment screw clockwise to reduce free travel. The pressure point moves away from the handlebar.

Turn the adjustment screw counterclockwise to increase free travel. The pressure point moves towards the handlebar.

The range of adjustment is limited.

Turn the adjusting screw by hand only, and do not apply any force.

Do not make any adjustments while riding!

• Check the free play of the hand brake lever. (P. 76)

Checking front brake fluid level

Warning

Danger of accidents Brake system failure.

• MINIf the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Danger of accidents Reduced braking due to old brake fluid.

• Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

• The brake fluid level must not fall below the center of the level viewer ① when the brake fluid reservoir is vertical.

If the brake fluid level is lower than the center of the level viewer:

• Add brake fluid for the front brake. (P. 78)

Adding brake fluid for front brake

Warning

Danger of accidents Brake system failure.

• MINIf the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.

MAINTENANCE WORK ON CHASSIS AND ENGINE

Warning

Skin irritations Brake fluid can cause skin irritation on contact.

• Avoid contact with skin and eyes, and keep out of the reach of children.
  If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking due to old brake fluid.

• Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Environmental hazard Problem materials cause environmental damage.

• Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Never user DOT 5 brake fluid! It is based on silicone oil and is colored purple. 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!

Use only clean brake fluid from a sealed container!

• Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

• Remove screws 1.
• Remove cover ② with membrane ③.
• Add brake fluid to level A.

Specification

Measurement of A

5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 (P. 166)

• Check parts for damage and wear. Replace damaged or worn parts.
  Position the cover with the membrane. Mount and tighten screws.

Clean up overflowed or spilt brake fluid immediately with water.

Brake linings

The brake linings fitted by KTM were tested over long periods and ensure optimal braking properties. The type names of brake pads are entered in the homologation documents.

Info

Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

Checking the front brake linings

Warning

Danger of accidents Reduced braking due to worn brake linings.

• Worn brake linings should be replaced immediately in an authorized KTM workshop.

Note

Danger of accidents Reduced braking due to damaged brake discs.

• If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are destroyed.

• Check the 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 linings. (P. 81)

Changing the front brake linings

Warning

Danger of accidents Improper brake maintenance and repair.

• Always have your brake system maintained and repaired in an authorized KTM workshop.

MAINTENANCE WORK ON CHASSIS AND ENGINE

Warning

Skin irritations Brake fluid can cause skin irritation on contact.

• Avoid contact with skin and eyes, and keep out of the reach of children.
  If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking due to old brake fluid.

• Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Danger of accidents Reduced braking 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 Reduced braking due to use of non-approved brake linings.

• Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

Warning

Environmental hazard Problem materials cause environmental damage.

• Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. 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!

Use only clean brake fluid from a sealed container!

• Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
• Remove screws 1.
• Remove the cover ② with membrane ③.
• Press the brake caliper by hand on to the brake disc in order to press back the brake pistons. Ensure that brake fluid does not overflow from the brake fluid reservoir and suction it off if necessary.

i Info Mak

Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.

• Remove split pin 4, remove bolt 5 toward the right by striking it and remove the brake linings.
• Clean brake caliper and brake caliper support.
• Check parts for damage and wear. Replace damaged or worn parts.

MAINTENANCE WORK ON CHASSIS AND ENGINE

• Check that leaf spring ⑥ in the brake caliper and sliding plate ⑦ in the brake caliper support are seated correctly.

• Insert the brake pads, insert the bolt and mount the split pin.

• Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot.

• Adjust the brake fluid level to level A. Specification

Measurement of A	5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 (P. 166)

Position the cover with the membrane. Mount and tighten screws.

Info

Clean up overflowed or spilt brake fluid immediately with water.

Checking free play of foot brake lever

Warning

Danger of accidents Brake system failure.

• If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can fail due to overheating. Adjust free travel on foot brake pedal according to specifications.

• Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel A.

Specification

Free play at foot brake lever

3... 5 mm (0.12... 0.2 in)

You will know that contact has been made with the foot brake cylinder piston when there is increased resistance when you activate the foot brake pedal.

If the free travel does not meet specifications:

• Adjust the basic position of the foot brake pedal. (P. 85)

Adjusting basic position of foot brake pedal

Warning

Danger of accidents Brake system failure.

• If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can fail due to overheating. Adjust free travel on foot brake pedal according to specifications.

• Remove screw connection ③ on foot brake cylinder 4.
• To adjust the basic position of the foot brake pedal as needed, loosen nut 1 and turn screw 2 accordingly.

The range of adjustment is limited. The screw must be screwed into the footrest bracket by at least four turns.

• Position foot brake cylinder 4 so that the foot brake pedal has the necessary free travel. Hold screws 3 in place and tighten the nuts.

Specification

Nut, foot brake cylinder screw

M6

10 Nm (7.4 lbf ft)

• Check the free play of the foot brake lever. (P. 85)
• Tighten nut 1.

Checking rear brake fluid level

Warning

Danger of accidents Brake system failure.

MINIf the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Danger of accidents Reduced braking due to old brake fluid.

• Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

• Stand the vehicle upright.
• Check the brake fluid level in the brake fluid reservoir.

If the fluid level reaches the MIN marking 1:

Top up the brake fluid of the rear brake. P.87

Topping up brake fluid of rear brake

Warning

Danger of accidents Brake system failure.

• MINIf the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Skin irritations Brake fluid can cause skin irritation on contact.

• Avoid contact with skin and eyes, and keep out of the reach of children.
  If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking due to old brake fluid.

• Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Environmental hazard Problem materials cause environmental damage.

• Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. 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! Use only clean brake fluid from a sealed container!

• Stand the vehicle upright.
• Remove screw cover ① with membrane ②.
  Top up the brake fluid to MAX level.

Brake fluid DOT 4 / DOT 5.1 (P. 166)

• Check parts for damage and wear. Replace damaged or worn parts.
• Refit screw with membrane.

Clean up overflowed or spilt brake fluid immediately with water.

Checking the rear brake linings

Warning

Danger of accidents Reduced braking due to worn brake linings.

• Worn brake linings should be replaced immediately in an authorized KTM workshop.

Note

Danger of accidents Reduced braking due to damaged brake discs.

• If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are destroyed.

• Check the brake linings for minimum thickness A .

Minimum thickness A ≥ 1 mm (≥0.04 in)

If the minimum thickness is less than specified:

• Change the rear brake linings. P. 89)

Changing rear brake linings

Warning

Danger of accidents Improper brake maintenance and repair.

• Always have your brake system maintained and repaired in an authorized KTM workshop.

Warning

Skin irritations Brake fluid can cause skin irritation on contact.

• Avoid contact with skin and eyes, and keep out of the reach of children.
  If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking due to old brake fluid.

• Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Danger of accidents Reduced braking 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 Reduced braking due to use of non-approved brake linings.

• Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

Warning

Environmental hazard Problem materials cause environmental damage.

• Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. 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!

Use only clean brake fluid from a sealed container!

• Stand the vehicle upright.
• Remove screw cover ① with membrane ②.
• Press the brake caliper by hand on to the brake disc in order to press back the brake piston. Ensure that brake fluid does not overflow from the brake fluid reservoir and suction it off if necessary.

Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.

• Remove split pin ③, remove bolt ④ toward the left by striking it and remove the brake linings.
• Clean brake caliper and brake caliper support.

• Check parts for damage and wear. Replace damaged or worn parts.

• Check that leaf spring ⑤ in the brake caliper and sliding plate ③ in the brake caliper support are seated correctly.

• Insert the brake pads, insert the bolt and mount the split pin.
• Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot.
• Adjust the brake fluid level to the MAX mark.

Brake fluid DOT 4 / DOT 5.1 (P. 166)

• Refit screw with membrane.

Clean up overflowed or spilt brake fluid immediately with water.

Removing front wheel

• Jack up the motorcycle. (P. 56)
• Press the brake caliper by hand on to the brake disc in order to press back the brake pistons.

MAINTENANCE WORK ON CHASSIS AND ENGINE

• Remove screw 1.

• Loosen screw ②.

• Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork.

Do not pull the hand brake lever when the front wheel is removed.

Always lay the wheel down in such a way that the brake disc is not damaged.

• Remove the spacing sleeves ③.

Fitting front wheel

Warning

Danger of accidents Reduced braking 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.

• Check parts for damage and wear. Replace damaged or worn parts.
• Clean and grease shaft seal rings 1 and bearing surface A of the spacing sleeves.

Long-life grease (P. 170)

• Fit the spacing sleeves.

• Lift the front wheel into the fork, position it, and insert the wheel spindle.
  Mount and tighten screw ②.

Specification

Screw, front wheel spindle

M24x1.5

40 Nm (29.5 lbf ft)

• Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc.
• Remove the motorcycle from the work stand. (P. 56)

• Pull the front wheel brake and push down hard on the fork several times to align the fork legs.

• Fully tighten screw .

Specification

Screw, fork stub

M8

15 Nm (11.1 lbf ft)

Removing rear wheel

• Jack up the motorcycle. (P. 56)
• Press the brake caliper by hand on to the brake disc in order to press back the brake piston.
• Remove nut ①. Remove chain adjuster ②.
• Holding the rear wheel, withdraw the wheel spindle ③.

Push the rear wheel forwards as far as possible and take the chain off the rear sprocket.

Warning

Danger of accidents Reduced braking due to damaged brake discs.

Always lay the wheel down in such a way that the brake disc is not damaged.

Take the rear wheel out of the swing arm.

Info

Do not operate the foot brake when the rear wheel is removed.

Fitting rear wheel

Warning

Danger of accidents Reduced braking 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.

• After installing the rear wheel, always operate the footbrake until the pressure point is reached.

• Checking the rear hub rubber dampers. P. 97
• Check parts for damage and wear. Replace damaged or worn parts.
• Remove the bushing ①. Clean and grease the roll surfaces of the bushing and the shaft seal ring ②.

Long-life grease (P. 170)

• Clean and grease the thread of the wheel spindle and nut ⑤.

Long-life grease (P. 170)

Mount the rubber damper and rear sprocket carrier in the rear wheel.
- Place the rear wheel in the swingarm and bring the brake disc on the brake caliper into contact.

MAINTENANCE WORK ON CHASSIS AND ENGINE

Push the rear wheel forward as far as possible and place the chain on the rear sprocket.
Mount the wheel spindle, chain adjuster and nut.

Specification

In order for the rear wheel to be correctly aligned, the markings on the left and right chain adjusters must be in the same position relative to the reference marks .

Info

Fit the chain left and right adjusters in similar positions.

• Tighten nut ⑤.

Specification

Nut, rear wheel spindle

M25x1.5

90 Nm (66.4 lbf ft)

• Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot.
• Remove the motorcycle from the work stand. (P. 56)

Checking the rear hub rubber dampers

Info

The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged.

• Remove the rear wheel. (P. 95)

• Check rubber dampers of the rear hub for damage and wear.
  If the rubber dampers of the rear hub are damaged or worn:

• Change all rubber dampers in the rear hub.

• Lay the read wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub.

• To check the play A , hold the rear wheel tight and try to rotate the rear sprocket.

Info Measure the play on the outside of the rear sprocket.

Play in rubber dampers, rear wheel

≤ 5 mm (≤ 0.2 in)

If the play A is more than the specified value:

• Change all rubber dampers in the rear hub.

• Fit the rear wheel. (P. 96)

Tire condition checking

Warning

Danger of accidents Uncontrollable handling behavior caused by a flat tire.

• For your own safety, have damaged tires changed immediately.

MAINTENANCE WORK ON CHASSIS AND ENGINE

Warning

Danger of crashing Impairment of riding behavior due to different tire tread patterns on front and rear wheels.

The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.

Warning

Danger of accidents Uncontrollable handling behavior caused by non-approved tires/wheels.

• Use only tires/wheels approved by KTM with the corresponding speed index.

Warning

Danger of accidents Reduced road grip with new tires.

• New tires have a smooth roll surface and therefore cannot provide full road grip. The entire roll surface must be roughened in the first 200 kilometers (124.3 miles) by moderate driving at alternating angles. The full grip is not reached until the vehicle has been run in.

Info

The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.

Worn tires have a negative effect on riding behavior, especially on wet surfaces.

• Check the front and rear tire for cuts, penetrations and other damage.

If the tires exhibits cuts, penetrations or other damage:

• Change the tires.

• Check the depth of the tread.

Info Note local national regulations concerning the minimum tread depth.
Minimum tread depth	≥ 2 mm (≥ 0.08 in)

If the minimum tread depth is insufficient:

• Change the tires.

Checking tire air pressure

Info

Low tire air pressure leads to abnormal wear and overheating of the tire.

Correct tire air pressure ensures optimal riding comfort and maximum tire service life.

• Remove dust cap.

• Check tire air pressure when tires are cold.

Tire air pressure, offroad, single rider
front	1.5 bar (22 psi)
Rear	1.5 bar (22 psi)
Tire air pressure, road, solo
front	1.8 bar (26 psi)
Rear	1.8 bar (26 psi)
Tire air pressure with passenger / fully loaded
front	2.0 bar (29 psi)
Rear	2.2 bar (32 psi)

If the tire pressure does not meet specifications:

• Correct tire pressure.

• Mount dust cap.

Checking spoke tension

Warning

Danger of accidents Unstable riding behavior due to loose spokes.

If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop.

Info

A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.

If the spokes are too tight, they can break due to local overload.

Check the spoke tension regularly, especially on a new motorcycle.

• To check spoke tension, tap each spoke with a screwdriver.

Specification

You should hear a high note.

Spoke nipple, front wheel	M5	4 Nm (3 lbf ft)
Spoke nipple, rear wheel	M5	4 Nm (3 lbf ft)

Info If you hear different tone frequencies from different spokes, this is an indication of different spoke tensions.

Removing the seat

Pull on strap 1 and raise the rear of the seat at the same time.
Pull back the seat and lift it off.

Mounting the seat

• Hook slot ① of the seat onto screw ②, press the rear downward and at the same time push it forward.
• Push locking pin ③ into lock housing ④ and push the back of the seat down until the locking pin locks in place with an audible click.
• Finally, check that the seat is correctly mounted.

Removing the battery

Warning

Risk of injury Battery acid and battery gases cause serious cauterization.

• Keep batteries out of the reach of children.
• Wear suitable protective clothing and goggles.
• Avoid contact with battery acid and battery gases.
• Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
  In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a doctor.

• Disconnect the negative (minus) cable of the battery.
  Pull off connector 1 in an upward direction.

• Remove screws ②.

Pull retaining bracket of the battery forward and remove it.
Take off the positive terminal cover 4.
- Disconnect the positive (plus) cable of the battery.
- Press the wiring harness to one side and pull the battery out of the battery rack.

Never operate the motorcycle with a discharged battery or without a battery. In both cases, electrical components can safety equipment can be damaged. The vehicle is then no longer safe to ride.

Installing the battery

• Slide the battery into the battery rack.

The battery terminals must be at the rear.

• Attach the positive cable and mount positive terminal cover 1.
  Position retaining bracket ②.
  Mount and tighten screws ③.

Specification

Remaining screws, chassis

M6

10 Nm (7.4 lbf ft)

Plug in connector 4.
- Attach the minus cable.
Mount the seat. (P. 103)

• Set the clock. (P. 29)

Recharging the battery

Warning

Risk of injury Battery acid and battery gases cause serious cauterization.

• Keep batteries out of the reach of children.
• Wear suitable protective clothing and goggles.
• Avoid contact with battery acid and battery gases.
• Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
  In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a doctor.

Warning

Environmental hazard Components and battery acid are a danger to the environment.

• Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.

Warning

Environmental hazard Problem materials cause environmental damage.

• Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Even if there is no load on the battery, it loses power every day.

The charge state and the type of charge are very important for the service life of the battery.

Fast recharging with a high charge current shortens the battery's service life.

If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes. The battery capacity is then reduced.

If the battery becomes discharged from starting, it must be recharged immediately.

If the battery rests for an extended time in a discharged state, it becomes over-discharged and sulfated, which will result in its destruction.

The battery is maintenance-free, i.e., the acid level does not have to be checked.

• Switch off all power-consuming components and switch off the engine.
• Remove the battery. P. 103)

MAINTENANCE WORK ON CHASSIS AND ENGINE

• Connect the battery charger to the battery. Switch on the battery charger.

Battery charger (58429074000)

You can also use the battery charger to test rest potential and start potential of the battery, and to test the generator. With this device, you cannot overcharge the battery.

Info Never remove the lid 1.

Charge the battery according to the instructions 2 on the battery casing.

After charging, switch off and disconnect the battery charger.

Specification

The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the motorcycle is not in use.	3 months

Install the battery. P. 104)

Changing the main fuse

Warning

Fire hazard The electrical system can be overloaded by the use of incorrect fuses.

• Use only fuses with the prescribed amperage. Never by-pass or repair fuses.

Info

The main fuse protects all power-consuming components of the vehicle. It is located in the housing of the electric starter relay next to the battery.

• Switch off all power-consuming components and switch off the engine.
• Remove the seat. (P. 102)

• Remove protection covers 1.

• Remove a defective main fuse ② with a needle nose plier.

• Check parts for damage and wear. Replace damaged or worn parts.

Info

A reserve fuse ③ is located in the starter relay.

• Fit a new main fuse.

Fuse (58011109130) (P. 158)

Info

If the new fuse burns out, contact an authorized KTM workshop.

• Check the functioning of the electrical equipment.

• Attach the protection covers.
  Mount the seat. (P. 103)

• Set the clock. (P. 29)

Changing fuses of individual power consumers

Info

The fuse box containing the fuses of individual power consumers is located under the seat.

• Switch off all power-consuming components and switch off the engine.
• Remove the seat. (P. 102)
• Open the fuse box cover ①.

• Remove defective fuse.

Specification

Fuse 1 - 10A - ignition, combination instrument, alarm system (optional)

Fuse 2 - 10A - clock, ignition (EFI control unit)

Fuse 3 - 10A - throttle valve control unit

Fuse 4 - 10A - fuel pump

Fuse 5 - 10A - radiator fan

Fuse 6 - 10A - horn, brake light, flasher light, alarm system (optional)

Fuse 7 - 15A - high beam, low beam, parking light, tail light, license plate lamp

Fuse 8 - 10A - for supplementary equipment (accessories connected with ignition switch)

Fuse 9 - 10A - for supplementary equipment (standard accessories)

Fuse 10 - not used

Fuse SPARE - 10A/15A - spare fuses

• Check parts for damage and wear. Replace damaged or worn parts.

Info A defective fuse is shown by a burned-out fuse wire

Warning

Fire hazard The electrical system can be overloaded by the use of incorrect fuses.

• Use only fuses with the prescribed amperage. Never by-pass or repair fuses.

Use spare fuses with the correct rating only.

Fuse (75011088010) (P. 158)

Fuse (75011088015) (P. 158)

Info

If the new fuse burns out, contact an authorized KTM workshop.

Tip

Replace the spare fuse in the fuse box so that it will be available if needed.

• Check the functioning of the power consumer.
• Close the fuse box cover.
  Mount the seat. (P. 103)

Adjusting the engine characteristic

• Switch off the ignition by turning the ignition key in the position
• Remove the seat. (P. 102)

• Pull the Map-Select switch and holder ① upward off of the retaining bracket.
  Pull the Map-Select switch out of the holder.

• Turn the adjusting wheel until the desired digit is next to marking ②.

Set the Map-Select switch to Soft.

• Set the adjusting wheel to position 1.

Soft - reduced homologated peak performance for better driveability.

Set the Map-Select switch to Advanced.

• Set the adjusting wheel to position 2.
  Advanced - homologated performance with extremely direct responsiveness.

Set the Map-Select switch to Standard.

• Set the adjusting wheel to position 3, 4, 5, 6, 7, 8 or 9.
  Standard - homologated performance with balanced responsiveness.

Set the Map-Select switch to poor fuel quality.

• Set the adjusting wheel to position 0.

Poor fuel quality - homologated performance is reduced in accordance with the fuel quality, use for no more than 1 tank of fuel

Position the Map-Select switch in the holder.
- Slide the Map-Select switch with the holder downward onto the retaining bracket.
Mount the seat. (P. 103)

Removing headlight mask with headlight

• Switch off all power-consuming components and switch off the engine.
• Protect the fender against damage by covering it with a cloth.
• Remove the screws ① on the left and right.
• Tilt the headlight mask forward and lift it off.

• Disconnect the connectors of flasher lights ① and headlight ②.
• Place the headlight mask to one side.

Refitting the headlight mask with the headlight

• Connect the connectors of headlight ① and flasher lights ②.
• Check lighting function.

• Remove the cloth from the fender, attach the headlight mask to points ③ on the fender and swing it up to the steering head.

Position brake-hose guide 4. Mount and tighten screws 5.

Specification

Remaining screws, chassis

M6

10 Nm (7.4 lbf ft)

Changing the headlight bulb

Note

Damage to reflector Keep the glass of the bulb free of grease.

Clean the glass bulb with a clean cloth before mounting. Any grease on the glass will evaporate by the heat and be deposited on the reflector.

• Remove the headlight mask with the headlight. (P. 113)
  Pull off connector 1.
  Take off rubber cap 2 of the headlight bulb.

• Detach spring bar ③.
• Remove headlight bulb 4.
• Insert a new headlight bulb into the headlight housing.

Headlight (H4/P43t) (P. 158)

• Fit the headlight bulb in the headlight using the spring bar.
• Replace the rubber cap. Attach the connector.
• Refit the headlight mask with the headlight. (P. 114)

Changing the parking light bulb

Note

Damage to reflector Keep the glass of the bulb free of grease.

Clean the glass bulb with a clean cloth before mounting. Any grease on the glass will evaporate by the heat and be deposited on the reflector.

• Remove the headlight mask with the headlight. (P. 113)
• Remove rubber cap 1.

Pull bulb socket out of the reflector.
Pull parking light bulb ③ out of the bulb socket.
- Check parts for damage and wear. Replace damaged or worn parts.
- Insert a new parking light bulb into the bulb socket.

Parking light (W2,1x9,5d) (P. 158)

• Insert the bulb socket into the reflector.
• Insert the rubber cap.
• Refit the headlight mask with the headlight. (P. 114)

Changing the flasher bulb

Note

Damage to reflector Keep the glass of the bulb free of grease.

Clean the glass bulb with a clean cloth before mounting. Any grease on the glass will evaporate by the heat and be deposited on the reflector.

• Remove the screw on the rear of the flasher housing.
• Carefully swing the diffuser ① forwards and remove it.
• Lightly pinch the orange cap ② at the holding points and remove it.
• Press the flasher bulb carefully into the holder, turn it about 30^ counterclockwise and remove it from the holder.

Do not touch the reflector with your fingers and try to avoid contact with oil or grease.

• Check parts for damage and wear. Replace damaged or worn parts.

• Press the new flasher bulb carefully into the holder and turn it clockwise as far as it will go.

Flasher light (BA15s) (P. 158)

Mount the orange cap.
Position the diffuser.
- Insert the screw and turn it first counterclockwise until you feel it click into the thread. Tighten the screw.
- Check the flasher function.

Checking headlamp setting

• On a light-colored wall with a horizontal area in front of it, make a mark as high as the center of the low beam headlight.
• Make another mark at a distance of under the first mark.

Specification

Distance ③

5 cm (2 in)

• Stand the motorcycle at a distance of A in front of the wall and switch on the low beam.

Specification

Distance A

5 m (16 ft)

• Check the headlamp setting.

The boundary between light and dark must be exactly on the lower mark for a motor-cycle with driver.

If the boundary between light and dark does not meet specifications:

• Adjust the headlight range. (P. 119)

Adjusting the headlight range

• Check the headlamp setting. (P. 118)
• Use a screwdriver (see illustration) to adjust the headlight range. Specification

The boundary between light and dark must be exactly on the lower mark for a motor-cycle with a rider (mark is applied under: Checking headlight adjustment).

Info

Turn clockwise to increase the light range, turn counterclockwise to reduce the light range.

If you have a payload, you may have to correct the headlight range.

Removing the air filter

• Remove the seat. (P. 102)
• Remove screws ①. Remove filter box top ②.

Note

Engine failure Unfiltered intake air has a negative effect on the service life of the engine.

• Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.

• Remove air filter ⑥.

Installing the air filter

• Check parts for damage and wear. Change damaged or worn parts. Change the air filter if it is dirty or wet.
  Clean the air filter box.
• Mount air filter ①.

The air filter must be in contact with the air filter box along the entire sealing surface A .

• Attach filter box top 2 at the front of the air filter box and swing it down.

MAINTENANCE WORK ON CHASSIS AND ENGINE

• Mount and tighten screws ③.

Specification

Remaining screws, chassis

M6

10 Nm (7.4 lbf ft)

Mount the seat. (P. 103)

Cooling system

The water pump 1 in the engine forces the coolant to flow.

The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap ②. Heat expansion causes excess coolant to flow into the compensating tank ③. If the temperature falls, the excess coolant is sucked back into the cooling system. The specified coolant temperature is therefore permissible without danger of function problems.

125 °C (257 °F)

The coolant is cooled by the air stream and a radiator fan 4, which is controlled by a thermoswitch.

The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect.

Checking the antifreeze and coolant level

Warning

Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure.

• Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.

Warning

Danger of poisoning Coolants are poisonous and a health hazard.

• Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

Condition

Engine is cold.

• Stand the motorcycle on its side stand on a horizontal surface.
• Remove the cap of the compensating tank ①.
• Check antifreeze of coolant.

-25... -45°C (-13... -49°F)

If the antifreeze of the cooling liquid does not meet specifications:

• Correct antifreeze of coolant.

• Check the coolant level in the compensating tank.

The coolant level must be within the range shown in the figure.

If the level of the cooling liquid does not meet specifications:

• Correct the coolant level.

Alternative 1

Coolant (P. 166)

Alternative 2

Coolant (mixed ready to use) (P. 166)

Mount the cap of the compensating tank.

• Screw off the radiator cap ②.
• Check antifreeze of coolant.

-25... -45°C (-13... -49°F)

If the antifreeze of the cooling liquid does not meet specifications:

• Correct antifreeze of coolant.

• Check the coolant level in the radiator.

The radiator must be completely full.

If the level of the cooling liquid does not meet specifications:

• Correct the coolant level and find out the cause of the loss.

Alternative 1

Coolant (P. 166)

Alternative 2

Coolant (mixed ready to use) (P. 166)

• Refit the radiator cap.

Checking the coolant level

Warning

Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure.

• Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.

Warning

Danger of poisoning Coolants are poisonous and a health hazard.

• Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

Condition

Engine is cold.

• Stand the motorcycle on its side stand on a horizontal surface.
• Check the coolant level in the compensating tank ①.

The coolant level must be within the range shown in the figure.

If the level of the cooling liquid does not meet specifications:

• Correct the coolant level.

Alternative 1

Coolant (P. 166)

Alternative 2

Coolant (mixed ready to use) (P. 166)

• Screw off the radiator cap 2 and check the coolant level in the radiator.

The radiator must be completely full.

If the level of the cooling liquid does not meet specifications:

• Correct the coolant level and find out the cause of the loss.

Alternative 1

Coolant (P. 166)

Alternative 2

Coolant (mixed ready to use) (P. 166)

• Refit the radiator cap.

Draining coolant

Warning

Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure.

• Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.

Warning

Danger of poisoning Coolants are poisonous and a health hazard.

• Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

• Stand the vehicle upright.
• Place a suitable container under the engine.
• Remove screw ①. Remove the radiator cap.
• Completely drain the coolant.
• Fit screw ① with a new seal and tighten it. Specification

Plug, drain hole of water pump

M10x1

15 Nm (11.1 lbf ft)

Install the engine guard. (P. 132)

Filling the cooling system

Warning

Danger of poisoning Coolants are poisonous and a health hazard.

• Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

• Stand the motorcycle on its side stand on a horizontal surface.
• Remove radiator cap ①.

• Refill the coolant.

Alternative 1

Coolant (P. 166)

Alternative 2

Coolant (mixed ready to use) P. 166

• Fill the radiator completely with coolant. Mount radiator cap ①.
• Remove the cap from compensating tank ② and add coolant to the level shown in the figure.
  Mount the cap of the compensating tank.

Danger

Danger of poisoning Exhaust gases are poisonous and can 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 a closed space.

• Start the engine and run it until the 5th bar of the temperature indicator lights up.

• Switch off the engine and allow it to cool down.
• After the engine has cooled down, check the coolant level in the radiator and in the compensating tank again and add more coolant if necessary.

Adjusting basic position of clutch lever

Info

Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.

Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar.

The range of adjustment is limited.

Turn the adjusting screw by hand only, and do not apply any force.

Do not make any adjustments while riding!

• Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw .

Checking/correcting fluid level of hydraulic clutch

Info

The fluid level rises with increasing wear of the clutch lining disc.

Do not use brake fluid.

• Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.

• Remove screws 1.
• Remove the cover ② with membrane ③.
• Check the fluid level.

Fluid level under top level of container. 4 mm (0.16 in)

If the fluid level does not meet specifications:

• Correct the fluid level of the hydraulic clutch.

Hydraulic fluid (15) (P. 167)

• Check parts for damage and wear. Replace damaged or worn parts.
  Position the cover with the membrane. Mount and tighten screws.

Checking play in gas Bowden cable

• Move the handlebar to the straight-ahead position. Move the throttle grip backwards and forwards to ascertain the play in the gas Bowden cable.

Play in gas Bowden cable 3...5 mm (0.12...0.2 in)

If the gas Bowden cable play does not meet specifications:

• Adjust the play in the gas Bowden cable. (P. 131)

Danger

Danger of poisoning Exhaust gases are poisonous and can 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 a closed space.

• Start the engine and let it run idle. Move the handlebar to and fro over the entire steering range.

The idle speed must not change.

If the idle speed changes:

• Adjust the play in the gas Bowden cable. (P. 131)

Adjusting play in gas Bowden cable

• Move the handlebar to the straight-ahead position.
• Loosen the lock nut ①.
• Adjust the play in the gas Bowden cable by turning the adjusting screw ② . Specification

Play in gas Bowden cable

3... 5 mm (0.12... 0.2 in)

• Tighten the lock nut ①.

Removing the engine guard

• Stand the motorcycle on its side stand on a horizontal surface.
• Remove screws ① on the left and right.
  Pull the engine guard forward out of the holders and set it down.

Installing the engine guard

• Slide the engine guard into holders at the rear.
  Position the engine guard. Mount and tighten screws.

Specification

Remaining screws, chassis

M6

10 Nm (7.4 lbf ft)

Checking engine oil level

Info

The engine oil level must be checked when the engine is at operating temperature.

• Stand the motorcycle upright on a horizontal surface.

Condition

The engine is at operating temperature.

• Check the engine oil level.

Info

After switching off the engine, wait for one minute and then check.

The engine oil must be between the lower and upper edge of the oil level viewer.

If the engine oil level is not at the specified level:

• Top up the engine oil. (P. 140)

Changing engine oil and oil filter, cleaning oil screens

• Drain the engine oil. (P. 134)
• Remove the oil filter. P. 135)
  Clean oil screens. P. 137
  Mount the oil filter. (P. 137)
• Fill up with engine oil. (P. 139)

Draining engine oil

Warning

Danger of scalding Engine oil and gear oil get very hot when the motorcycle is driven.

• Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning

Environmental hazard Problem materials cause environmental damage.

• Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Drain the engine oil only when the engine is warm.

• Remove the engine guard. (P. 132)
• Place a suitable container under the engine.
• Remove the oil drain plug ① with the magnet and seal ring.
• Completely drain the engine oil.

Thoroughly clean the oil drain plug with a magnet.
- Check parts for damage and wear. Replace damaged or worn parts.
- Refit the oil drain plug with the magnet and seal ring and tighten it. Specification

Oil drain plug with magnet

M12x1,5

20 Nm (14.8 lbf ft)

Removing the oil filter

Warning

Danger of scalding Engine oil and gear oil get very hot when the motorcycle is driven.

Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning

Environmental hazard Problem materials cause environmental damage.

• Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

• Place a suitable container under the engine.

• Remove screws ①. Remove oil filter cover ② with O-ring.
  Pull the oil filter insert ③ out of the oil filter casing.

Circlip pliers reverse (51012011000)

• Remove screws ④. Remove oil filter cover ⑤ with O-ring.
  Pull the oil filter insert ⑥ out of the oil filter casing.

Circlip pliers reverse (51012011000)

• Completely drain the engine oil.
  Thoroughly clean parts and sealing area.

Mounting oil filter

• Check parts for damage and wear. Replace damaged or worn parts.
  Insert oil filter 1 and 2.
  Oil the O-rings of the oil filter cover. Refit the oil filter cover 3 and 4.
  Mount and tighten screws.

Specification

Screw, oil filter cover

M5

6 Nm (4.4 lbf ft)

Cleaning oil screens

Warning

Danger of scalding Engine oil and gear oil get very hot when the motorcycle is driven.

• Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning

Environmental hazard Problem materials cause environmental damage.

• Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

• Place a suitable container under the engine.

• Remove the plug ① with the oil screen ② and O-rings.

• Remove the plug ③ with the oil screen ④ and O-rings.

• Drain the remaining engine oil.
  Thoroughly clean parts and sealing area.
• Check parts for damage and wear. Replace damaged or worn parts.

Position oil screen ⑤ with O-rings.
- Refit plug ⑥ with O-ring and tighten it.

Specification

Plug, oil screen

M20x1,5

15 Nm (11.1 lbf ft)

MAINTENANCE WORK ON CHASSIS AND ENGINE

Position oil screen 7 with O-rings.
- Refit plug ⑧ with O-ring and tighten it.

Specification

Plug, oil screen

M20x1,5

15 Nm (11.1 lbf ft)

Filling up with engine oil

Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

• Remove filler plug with O-ring ① from the clutch cover and add engine oil.

Engine oil

1.70 l (1.8 qt.)

Engine oil (SAE 10W/60) (● P. 167)

• Refit plug with O-ring 1 and tighten it.

Danger

Danger of poisoning Exhaust gases are poisonous and can 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 a closed space.

• Start the engine and check that it is oil-tight.
  Install the engine guard. (P. 132)

• Check the engine oil level. (P. 133)

Topping up engine oil

Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

• Remove filler plug with O-ring ① from the clutch cover and add engine oil.

Engine oil (SAE 10W/60) (P. 167)

• Refit plug with O-ring 1 and tighten it.

Danger

Danger of poisoning Exhaust gases are poisonous and can 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 a closed space.

• Start the engine and check that it is oil-tight.

• Check the engine oil level. (P. 133)

Faults	Possible cause	Action
Engine does not turn when the electric starter button is pressed	Operating error	- Carry out the instructions for starting. (P. 43)
	Battery discharged	- Recharge the battery. (P. 105) - Check the cause of discharging.
	Fuse 1, 2, 3, or 4 blown	- Change the fuses of individual power consumers. (P. 109)
	Main fuse burned out	- Change the main fuse. (P. 107)
	Ignition/steering lock or emergency OFF switch defective	- Have ignition/steering lock or emergency OFF switch checked.
	Defect in safety start system	- Have the safety start system checked.
Engine turns only if the clutch lever is drawn	The vehicle is in gear	- Shift gear to neutral.
	The vehicle is in gear and the side stand is folded out	- Shift gear to neutral.
	Defect in safety start system	- Have the safety start system checked.
Engine turns although a gear is engaged	Defect in safety start system	- Have the safety start system checked.
Engine turns but does not start.	Operating error	- Carry out the instructions for starting. (P. 43)
	Fuse 4 blown	- Change the fuses of individual power consumers. (P. 109)
	Coupling of fuel hose connection not connected	- Reconnect coupling of fuel hose connection.
	Socket connector of cable harness oxidized	- Clean socket connector and treat it with contact spray.
	Defect in fuel injection system	- Read the error memory with the KTM diagnostics tool and correct the fault.
Engine has too little power.	Air filter very dirty	- Have the air filter changed.
Engine has too little power.	Fuel filter very dirty	- Have the fuel filter changed.
	Defect in fuel injection system	- Read the error memory with the KTM diagnostics tool and correct the fault.
Engine overheats.	Too little coolant in cooling system	- Check the cooling system for leakage. - Check the coolant level. (P. 124)
	Radiator fins very dirty	- Clean radiator fins.
	Foam formation in cooling system	- Drain the coolant. (P. 126) - Fill the cooling system. (P. 127)
	Buckled or damaged radiator hose	- Have the radiator hose changed.
	Thermostat defective	- Have thermostat checked.
	Fuse 5 blown	- Change the fuses of individual power consumers. (P. 109)
	Defect in radiator fan system	- Have the radiator fan system checked.
	Air in cooling system	- Fill the cooling system. (P. 127)
FI warning lamp (MIL) lights/flashes	Defect in fuel injection system	- Read the error memory with the KTM diagnostics tool and correct the fault.
Engine dies during the journey	Lack of fuel	- Fill up with fuel. (P. 51)
	Fuse 1, 2 or 4 blown	- Change the fuses of individual power consumers. (P. 109)
High oil consumption	Engine vent hose bent	- Route the vent hose without bends or change it if necessary.
	Engine oil level too high	- Check the engine oil level. (P. 133)
	Engine oil too thin (low viscosity)	- Change engine oil and oil filter, clean oil screens. (P. 133)
Headlight and parking light not functioning	Fuse 7 blown	- Change the fuses of individual power consumers. (▼ P. 109)
Flasher light, brake light and horn not functioning	Fuse 6 blown	- Change the fuses of individual power consumers. (▼ P. 109)
Time is not (correctly) displayed	Fuse 2 blown	- Change the fuses of individual power consumers. (▼ P. 109) - Set the clock. (▼ P. 29)
Battery discharged	Ignition not switched off when vehicle was parked	- Recharge the battery. (▼ P. 105)
	Battery is not charged by generator	- Check charging voltage.
Combination instrument shows nothing in the display	Fuse 1 blown	- Change the fuses of individual power consumers. (▼ P. 109)
Speedometer in combination instrument not functioning	Speedometer cable harness damaged or plug oxidized	- Have the cable harness and plug checked.

Fault	Description	Possible cause	Action
02	FI warning lamp (MIL) flashes briefly 2x	Malfunction in ignition pulse generator circuit	- Check the ignition pulse generator.
06	FI warning lamp (MIL) flashes briefly 6x	Input signal from throttle valve sensor too low/high	- Check the throttle valve sensor.
08	FI warning lamp (MIL) flashes briefly 8x	Input signal from throttle grip sensor too low/high	- Check the throttle grip sensor.
09	FI warning lamp (MIL) flashes briefly 9x	Input signal from pressure sensor of induction manifold too low/high	- Check the pressure sensor of the induction manifold.
12	FI warning lamp (MIL) flashes 1x long, 2x short	Input signal from coolant temperature sensor too low/high	- Check the temperature sensor coolant.
13	FI warning lamp (MIL) flashes 1x long, 3x short	Input signal from intake air temperature sensor too low/high	- Check the intake air temperature sensor.
14	FI warning lamp (MIL) flashes 1x long, 4x short	Input signal from ambient air pressure sensor too low/high	- Check the ambient air pressure sensor.
15	FI warning lamp (MIL) flashes 1x long, 5x short	Input signal from roll angle sensor too low/high	- Check the roll angle sensor.
17	FI warning lamp (MIL) flashes 1x long, 7x short	Malfunction in lambda probe circuit	- Check the lambda probe.
24	FI warning lamp (MIL) flashes 2x long, 4x short	Malfunction in voltage supply circuit of EFI control unit	- Check the EFI control unit voltage supply.
25	FI warning lamp (MIL) flashes 2x long, 5x short	Malfunction in side stand switch circuit	- Check the side stand switch.
26	FI warning lamp (MIL) flashes 2x long, 6x short	Malfunction in Hall sensor throttle valve control circuit	- Check the Hall sensor throttle valve control.
27	FI warning lamp (MIL) flashes 2x long, 7x short	Malfunction in voltage supply circuit of throttle valve control unit	- Check the throttle valve control unit voltage supply.
33	FI warning lamp (MIL) flashes 3x long, 3x short	Malfunction in injection valve circuit	- Check the injection valve.
37	FI warning lamp (MIL) flashes 3x long, 7x short	Malfunction in ignition coil circuit	- Check the ignition coil.
41	FI warning lamp (MIL) flashes 4x long, 1x short	Fault/short-circuit in fuel pump control circuit	- Check the fuel pump control.
45	FI warning lamp (MIL) flashes 4x long, 5x short	Malfunction or short-circuit after positive in lambda probe heating circuit	- Check the lambda probe heating.
54	FI warning lamp (MIL) flashes 5x long, 4x short	Fault/short-circuit in secondary air valve circuit	- Check the secondary air valve.
55	FI warning lamp (MIL) flashes 5x long, 5x short	Malfunction in throttle valve control unit circuit (internal)	- Check the throttle valve control unit.
58	FI warning lamp (MIL) flashes 5x long, 8x short	Malfunction in release of throttle stepper in EPT mode	- Check the throttle valve control unit. - Check the EFI control unit.
60	FI warning lamp (MIL) flashes 6x long	Malfunction in throttle stepper circuit	- Check the throttle stepper motor.
68	FI warning lamp (MIL) flashes 6x long, 8x short	Connection of pressure sensor of induction manifold leaky	- Check the connection of the pressure sensor of the induction manifold.
90	FI warning lamp (MIL) flashes 9x long	Throttle valve position not plausible	- Check the throttle valve position.
91	FI warning lamp (MIL) flashes 9x long, 1x short	Malfunction in CAN bus com-munication	- Check CAN bus communica-tion.
92	FI warning lamp (MIL) flashes 9x long, 2x short	Malfunction in voltage supply circuit of throttle valve control unit (internal)	- Check the throttle valve con-trol unit.

Cleaning motorcycle

Note

Material damage Damage and destruction of components by high-pressure cleaning equipment.

• Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts.

Warning

Environmental hazard Problem materials cause environmental damage.

• Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

If you clean the motorcycle regularly, its value and appearance are maintained over a long period. Avoid direct sunshine on the motorcycle during cleaning.

Before you clean the motorcycle, seal the exhaust system to prevent penetration by water.
- First remove coarse dirt particles with a gentle water spray.
Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush.

Motorcycle cleaner (P. 170)

Info

Use warm water containing normal motorcycle cleaner and a soft sponge.

If you have ridden the vehicle on salted roads, clean it with cold water. Warm water would reinforce the effect of the salt.

After rinsing the motorcycle thoroughly with a soft jet of water, dry it with compressed air and a cloth.

Warning

Danger of accidents Reduced braking due to wet or dirty brakes.

Clean or dry dirty or wet brakes by riding and braking gently.

After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes.

Info

The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.

• Push back the protection covers on the handlebar instruments to allow water to evaporate.
• After the motorcycle has cooled off, oil or grease all moving parts and bearings.
  Clean the chain. (P. 69)
  Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.

Cleaning and polishing materials for metal, rubber and plastic (P. 169)

Treat all painted parts with a mild paint polish.

High-luster polish for paint (P. 169)

• To prevent electrical problems, treat electric contacts and switches with contact spray.

Contact spray (P. 169)

Oil the ignition/steering lock.

Universal oil spray (P. 170)

Conservation for winter operation

Info

If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt.

If you have ridden the vehicle on salted roads, clean it with cold water. Warm water would reinforce the effect of the salt.

Clean the motorcycle. (P. 147)
Treat the engine, the swingarm, and all other bare or galvanized parts (except brake discs) with a wax-based anti-corrosion substance.

Info

To prevent serious reduction of the braking efficiency, make sure no anti-corrosion substance gets on to the brake discs. After use on salted roads, clean the motorcycle thoroughly with cold water and dry it properly.

Clean the chain. (P. 69)

Storage

Info

If you want to garage the motorcycle for a longer period, take the following actions.

Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season.

• Make sure the tank is as empty as possible so that you can fill up with fresh fuel when you put the motorcycle back into operation.
  Clean the motorcycle. (P. 147)
• Change engine oil and oil filter, clean oil screens. P. 133
• Check the antifreeze and coolant level. (P. 122)
• Checking the tire air pressure. (P. 100)
• Remove the battery. (P. 103)
• Recharge the battery. (P. 105)

Specification

Storage temperature of battery without direct sunshine.

0...35°C (32...95°F)

• The storage place should be dry and not subject to large temperature differences.

Info

KTM recommends jacking up the motorcycle.

• Jack up the motorcycle. (P. 56)

Cover the motorcycle with a porous sheet or blanket.

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 condenses and causes valves and exhaust system to rust.

Putting into operation after storage

• Remove the motorcycle from the work stand. (P. 56)
• Recharge the battery. P. 105)
  Install the battery. P. 104)
• Set the clock. (P. 29)
• Fill up with fuel. (P. 51)
• Carry out checks before putting into operation. (P. 42)
• Make a test ride.

Design	1-cyliner 4-stroke engine, water-cooled
Displacement	654 cm³ (39.91 cu in)
Stroke	80 mm (3.15 in)
Bore	102 mm (4.02 in)
Compression ratio	11,8:1
Control	OHC, 4 valves controlled via rocker arm, chain drive
Valve diameter, intake	40 mm (1.57 in)
Valve diameter, exhaust	34 mm (1.34 in)
Valve play, cold	0.07... 0.13 mm (0.0028... 0.0051 in)
Crankshaft bearing	2 roller bearings
Conrod bearing	Needle bearing
Piston pin bearing	Bronze bush
Pistons	Forged light alloy
Piston rings	1 L-ring, 1 tapered compression piston ring, 1 oil scraper ring
Engine lubrication	Pressure circulation lubrication with 2 rotor pumps
Primary transmission	36:79
Clutch	APTC antihopping clutch in oil-bath / hydraulically actuated
Gearbox	6-gears, claw-shifted
Transmission ratio
1st gear	14:35
2nd gear	16:28
3rd gear	21:28
4th gear	21:23
5th gear	23:22
6th gear	23:20
Mixture preparation	Electronic fuel injection
Ignition	Contactless controlled fully electronic ignition with digital ignition adjustment
Generator	12 V, 224 W
Spark plug	NGK LKAR 8AI - 9
spark plug electrode gap	0.9 mm (0.035 in)
Cooling	Water cooling, permanent circulation of coolant by water pump
Starting aid	Electric starter, automatic decompressor

Capacity - engine oil

Engine oil

1.70 l (1.8 qt.)

Engine oil (SAE 10W/60) (● P. 167)

Capacity - coolant

Coolant	1.20 l (1.27 qt.)	Coolant (● P. 166)
		Coolant (mixed ready to use) (● P. 166)

TECHNICAL DATA - ENGINE TIGHTENING TORQUES

Plug, oil bore	self-tapping	9 Nm (6.6 lbf ft)	Loctite® 243TM
Screw, membrane fixation	M3	2.5 Nm (1.84 lbf ft)	Loctite® 243TM
Oil jet, conrod lubrication	M4	2 Nm (1.5 lbf ft)	Loctite® 243TM
Hose clamp, intake flange	M4	1.5 Nm (1.11 lbf ft)	-
Screw, cover plate for oil return line	M5	6 Nm (4.4 lbf ft)	-
Screw, breather cover on valve cover	M5	3 Nm (2.2 lbf ft)	Loctite® 243TM
Screw, gear sensor	M5	5 Nm (3.7 lbf ft)	Loctite® 243TM
Screw, clutch spring	M5	6 Nm (4.4 lbf ft)	-
Locking screw for bearing	M5	6 Nm (4.4 lbf ft)	Loctite® 648TM
Screw, oil filter cover	M5	6 Nm (4.4 lbf ft)	-
Screw, oil pump cover	M5	6 Nm (4.4 lbf ft)	Loctite® 243TM
Oil jet, piston cooling	M6x0.75	4 Nm (3 lbf ft)	Loctite® 243TM
Screw, locking lever	M6	10 Nm (7.4 lbf ft)	Loctite® 243TM
Screw, Autodecompression	M6	3... 4 Nm (2.2... 3 lbf ft)	Loctite® 243TM
Screw, axial lock of camshaft	M6	10 Nm (7.4 lbf ft)	Loctite® 243TM
Screw, timing chain guide rail	M6	10 Nm (7.4 lbf ft)	Loctite® 243TM
Screw generator cover	M6	10 Nm (7.4 lbf ft)	-
Screw in generator cover (chain shaft through-hole)	M6	10 Nm (7.4 lbf ft)	Loctite® 243TM
Screw, ignition pulse generator	M6	10 Nm (7.4 lbf ft)	Loctite® 243TM
Screw, rocker arm shaft	M6	12 Nm (8.9 lbf ft)	-
Screw, clutch cover	M6	10 Nm (7.4 lbf ft)	-
Screw, clutch slave cylinder	M6x20	10 Nm (7.4 lbf ft)	Loctite® 243TM
Screw, clutch slave cylinder	M6x35	10 Nm (7.4 lbf ft)	-

TECHNICAL DATA - ENGINE TIGHTENING TORQUES

Screw, engine housing	M6	10 Nm (7.4 lbf ft)	-
Screw, shift drum locating	M6	10 Nm (7.4 lbf ft)	Loctite® 243™
Screw, shift lever	M6	10 Nm (7.4 lbf ft)	Loctite® 222
Screw, timing chain tensioning rail	M6	10 Nm (7.4 lbf ft)	Loctite® 243™
Screw, starter motor	M6	10 Nm (7.4 lbf ft)	Loctite® 243™
Screw, stator bracket	M6	10 Nm (7.4 lbf ft)	Loctite® 243™
Screw, thermostat housing	M6	10 Nm (7.4 lbf ft)	Loctite® 243™
Screw, valve cover	M6	10 Nm (7.4 lbf ft)	-
Screw, water pump cover	M6	10 Nm (7.4 lbf ft)	-
Screw, water pump wheel	M6	10 Nm (7.4 lbf ft)	Loctite® 243™
Screw, cylinder	M6	10 Nm (7.4 lbf ft)	Loctite® 243™
Screw, cylinder head	M6	10 Nm (7.4 lbf ft)	Loctite® 243™
Plug, vacuum connection	M6	10 Nm (7.4 lbf ft)	Loctite® 243™
Stud, exhaust flange	M8	10 Nm (7.4 lbf ft)	Loctite® 243™
Plug, crankshaft location	M8	20 Nm (14.8 lbf ft)	-
Screw, unlocking of timing chain tensioner	M10x1	10 Nm (7.4 lbf ft)	-
Plug, drain hole of water pump	M10x1	15 Nm (11.1 lbf ft)	-
Plug, oil bore for oil radiator	M10x1	15 Nm (11.1 lbf ft)	-
Plug, oil bore	M10x1	15 Nm (11.1 lbf ft)	Loctite® 243™

TECHNICAL DATA - ENGINE TIGHTENING TORQUES

Screw, cylinder head	M10	Tightening sequence: Tighten diagonally, beginning with the rear screw on the chain shaft. Step 1 15 Nm (11.1 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 45 Nm (33.2 lbf ft) Step 4 60 Nm (44.3 lbf ft)	lubricated with engine oil
Spark plug	M12x1,25	17 Nm (12.5 lbf ft)	-
Coolant temperature sensor on cylinder head	M12x1.5	12 Nm (8.9 lbf ft)	-
Oil drain plug with magnet	M12x1,5	20 Nm (14.8 lbf ft)	-
Oil pressure regulator valve plug	M12x1.5	20 Nm (14.8 lbf ft)	-
Plug, oil bore	M14x1,5	15 Nm (11.1 lbf ft)	Loctite® 243TM
Engine case stud	M16x1.5	25 Nm (18.4 lbf ft)	Loctite® 243TM
Ignition rotor nut	M18x1,5	100 Nm (73.8 lbf ft)	-
Nut, engine sprocket	M20x1,5	60 Nm (44.3 lbf ft)	Loctite® 243TM
Nut, inner clutch hub	M20x1,5	100 Nm (73.8 lbf ft)	Loctite® 243TM
Nut, primary gear	M20LHx1,5	100 Nm (73.8 lbf ft)	Loctite® 243TM
Plug, oil screen	M20x1,5	15 Nm (11.1 lbf ft)	-
Plug, timing chain tensioner	M20x1,5	25 Nm (18.4 lbf ft)	-
Screw in generator cover	M24x1.5	8 Nm (5.9 lbf ft)	-
Plug, oil thermostat	M24x1,5	15 Nm (11.1 lbf ft)	-

Frame	Lattice frame made of chrome molybdenum steel tubing, powder-coated
Fork	WP 4860 MXMA
Shock absorber	WP Suspension 4618 with Pro-Lever deflector
Suspension travel
front	250 mm (9.84 in)
Rear	250 mm (9.84 in)
Brake system
front	Disc brake with dual-piston brake caliper, floating
Rear	Disc brake with single-piston brake caliper, floating
Diameter of brake discs
front	300 mm (11.81 in)
Rear	240 mm (9.45 in)
Wear limit of brake discs
front	4.5 mm (0.177 in)
Rear	3.5 mm (0.138 in)
Tire air pressure, road, solo
front	1.8 bar (26 psi)
Rear	1.8 bar (26 psi)
Tire air pressure with passenger / fully loaded
front	2.0 bar (29 psi)
Rear	2.2 bar (32 psi)
Tire air pressure, offroad, single rider
front	1.5 bar (22 psi)
Rear	1.5 bar (22 psi)
Rear wheel gearing	15:45
Chain	5/8 x 1/4” X-ring
Steering head angle	63°
Wheelbase	1,498±15 mm (58.98±0.59 in)
Seat height unloaded	910 mm (35.83 in)
Ground clearance unloaded	300 mm (11.81 in)
Weight without fuel	138.5 kg (305.3 lb.)
Maximum permissible front axle load	150 kg (331 lb.)
Maximum permissible rear axle load	200 kg (441 lb.)
Maximum permissible overall weight	350 kg (772 lb.)

Battery	YTZ10S	Battery voltage: 12 V Nominal capacity: 8.6 Ah maintenance-free
Fuse	58011109130	30 A
Fuse	75011088015	15 A
Fuse	75011088010	10 A

Lighting equipment

Headlight	H4/P43t	12 V 60/55 W
Parking light	W2,1x9,5d	12 V 5 W
Instrument lights and indicator lamps	LED
Flasher light	BA15s	12 V 10 W
Brake / tail light	LED
Licence plate lamp	W2,1x9,5d	12 V 5 W

Front tire	Rear tire
90/90 - 21 54 H TL Metzeler Enduro 3 Sahara	140/80 - 18 70 H TL Metzeler Enduro 3 Sahara
For further information, see the Service section under: http://www.ktm.com

Capacity - fuel

Fuel tank content	12 l (3.2 US gal)	Super unleaded (ROZ 95 / RON 95 / PON 91) (P. 168)
Fuel reserve		2.5 l (2.6 qt.)
Fork part number		14.18.7D.11
Fork		WP 4860 MXMA
Compression damping
Comfort		20 clicks
Standard		15 clicks
Sport		10 clicks
full payload		10 clicks
Rebound damping
Comfort		20 clicks
Standard		15 clicks
Sport		10 clicks
full payload		10 clicks
Spring length with preload spacer(s)		472 mm (18.58 in)
Spring rate
Weight of rider: 75... 85 kg (165... 187 lb.)		5.4 N/mm (30.8 lb/in)
Air chamber length		110±20 mm (4.33±0.79 in)
Fork length		890 mm (35.04 in)
Fork oil (P. 167)		SAE 5
Shock absorber part number		15.18.7D.11
Shock absorber		WP Suspension 4618 with Pro-Lever deflector
Compression damping, high-speed
Comfort		2 turns
Standard		1.5 turns
Sport		1 turn
full payload		1 turn
Compression damping, low-speed
Comfort		20 clicks
Standard		15 clicks
Sport		10 clicks
full payload		10 clicks
Rebound damping
Comfort		20 clicks
Standard		15 clicks
Sport		10 clicks
full payload		10 clicks
Spring preload		19 mm (0.75 in)
Spring rate
Weight of rider: 75... 85 kg (165... 187 lb.)		80 N/mm (457 lb/in)
Spring length		220 mm (8.66 in)
Gas pressure		10 bar (145 psi)
Static sag		25 mm (0.98 in)
Riding sag		80... 90 mm (3.15... 3.54 in)

TECHNICAL DATA - SHOCK ABSORBER

Fitted length

395 mm (15.55 in)

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES

Remaining screws, chassis	M5	4 Nm (3 lbf ft)	-
Spoke nipple, front wheel	M5	4 Nm (3 lbf ft)	-
Spoke nipple, rear wheel	M5	4 Nm (3 lbf ft)	-
Screw, exhaust heat shield	M5	8 Nm (5.9 lbf ft)	-
Screw, electrical holder	M5	3 Nm (2.2 lbf ft)	-
Screw, footbrake pedal foothold	M5	6 Nm (4.4 lbf ft)	Loctite® 243™
Screw, fuel pump	M5	6 Nm (4.4 lbf ft)	-
Screw, fuel level indicator	M5	3 Nm (2.2 lbf ft)	-
Screw, side cover	M5	2 Nm (1.5 lbf ft)	-
Screw, headlight mask	M5	5 Nm (3.7 lbf ft)	-
Screw, side stand switch	M5	3 Nm (2.2 lbf ft)	-
Screw, seat lock	M5	3 Nm (2.2 lbf ft)	Loctite® 222
Screw, starter cable on starter	M5	3 Nm (2.2 lbf ft)	-
Nut, foot brake cylinder screw	M6	10 Nm (7.4 lbf ft)	-
Remaining nuts, chassis	M6	15 Nm (11.1 lbf ft)	-
Remaining screws on fuel tank	M6	6 Nm (4.4 lbf ft)	-
Remaining screws, chassis	M6	10 Nm (7.4 lbf ft)	-
Screw, brake fluid reservoir of rear brake	M6	5 Nm (3.7 lbf ft)	-
Screw, rear brake disc	M6	14 Nm (10.3 lbf ft)	Loctite® 243™
Screw, front brake disc	M6	14 Nm (10.3 lbf ft)	Loctite® 243™
Screw, license plate holder, bottom	M6	8 Nm (5.9 lbf ft)	-
Screw, ball joint of push rod on foot-brake cylinder	M6	10 Nm (7.4 lbf ft)	Loctite® 243™
Screw, radiator bracket	M6	5 Nm (3.7 lbf ft)	-

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES

Screw, magnetic holder on side stand	M6	10 Nm (7.4 lbf ft)	Loctite® 243TM
Screw, voltage regulator/rectifier	M6	8 Nm (5.9 lbf ft)	-
Screw, SLS valve	M6	4 Nm (3 lbf ft)	-
Screw, ignition lock	M6	10 Nm (7.4 lbf ft)	Loctite® 243TM
Nut, rear sprocket screw	M8	35 Nm (25.8 lbf ft)	Loctite® 243TM
Nut, manifold on cylinder head	M8	25 Nm (18.4 lbf ft)	Copper paste
Remaining nuts, chassis	M8	30 Nm (22.1 lbf ft)	-
Remaining screws, chassis	M8	25 Nm (18.4 lbf ft)	-
Screw, exhaust clamp on main silencer	M8	25 Nm (18.4 lbf ft)	-
Screw, front brake caliper	M8	25 Nm (18.4 lbf ft)	Loctite® 243TM
Screw, main silencer holder	M8	25 Nm (18.4 lbf ft)	-
Screw, main silencer holder on fuel tank	M8	25 Nm (18.4 lbf ft)	Loctite® 243TM
Screw, rear footrest bracket	M8x16	25 Nm (18.4 lbf ft)	-
Screw, front footrest bracket	M8	25 Nm (18.4 lbf ft)	-
Screw, spring holder on side stand bracket	M8	25 Nm (18.4 lbf ft)	Loctite® 243TM
Screw, top triple clamp	M8	17 Nm (12.5 lbf ft)	-
Screw, bottom triple clamp	M8	12 Nm (8.9 lbf ft)	-
Screw, fork stub	M8	15 Nm (11.1 lbf ft)	-
Screw, steering stem	M8	20 Nm (14.8 lbf ft)	Loctite® 243TM
Screw, handrail	M8	20 Nm (14.8 lbf ft)	-
Screw, license plate holder, top	M8	20 Nm (14.8 lbf ft)	-
Screw, fuel tank, top	M8	25 Nm (18.4 lbf ft)	Loctite® 243TM
Screw, fuel tank, bottom	M8	25 Nm (18.4 lbf ft)	-

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES

Screw, handlebar clamp	M8	20 Nm (14.8 lbf ft)	Loctite® 243™
Screw, side stand bracket	M8	25 Nm (18.4 lbf ft)	-
Screw, connection lever on frame	M8	30 Nm (22.1 lbf ft)	-
Remaining nuts, chassis	M10	50 Nm (36.9 lbf ft)	-
Remaining screws, chassis	M10	45 Nm (33.2 lbf ft)	-
Engine carrying screw	M10	45 Nm (33.2 lbf ft)	Loctite® 243™
Screw, top shock absorber	M10	45 Nm (33.2 lbf ft)	Loctite® 243™
Screw, bottom shock absorber	M10	45 Nm (33.2 lbf ft)	Loctite® 243™
Screw, foot brake pedal	M10LH	25 Nm (18.4 lbf ft)	Loctite® 243™
Screw, handlebar support	M10	40 Nm (29.5 lbf ft)	-
Screw, engine bearer on frame	M10	45 Nm (33.2 lbf ft)	-
Screw, side stand	M10	35 Nm (25.8 lbf ft)	Loctite® 243™
Lambda probe	M12x1.25	24.5 Nm (18.07 lbf ft)	-
Screw, swingarm pivot	M12x1.75	80 Nm (59 lbf ft)	-
Nut, linkage lever to rocker arm	M14x1.5	100 Nm (73.8 lbf ft)	-
Nut, linkage lever on swingarm	M14x1.5	100 Nm (73.8 lbf ft)	-
Screw, top steering head	M20x1.5	10 Nm (7.4 lbf ft)	-
Screw, bottom steering head	M20x1.5	60 Nm (44.3 lbf ft)	Loctite® 243™
Screw, front wheel spindle	M24x1.5	40 Nm (29.5 lbf ft)	-
Nut, rear wheel spindle	M25x1.5	90 Nm (66.4 lbf ft)	-

Brake fluid DOT 4 / DOT 5.1

according to

• DOT

Specification

• Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Castrol and Motorex® products.

Supplier

Castrol

- Brake Fluid DOT 5.1

Coolant

Specification

• Use only suitable coolant (even in countries with high temperatures). Using inferior antifreeze can result in corrosion and foaming. KTM recommends Motorex® products.

Mixture ratio

Antifreeze: -25... -45 °C (-13... -49 °F)

50 % Anti-corrosion/antifreeze 50 % distilled water

Coolant (mixed ready to use)

Antifreeze

-40 °C (-40 °F)

Supplier

Motorex®

Anti Freeze

Engine oil (SAE 10W/60)

according to

JASOT903MA(P.171)
SAE (P. 171) (SAE 10W/60)

Specification

• Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex® products.

Synthetic engine oil

Supplier

Motorex®

Cross Power 4T

Fork oil (SAE 5)

according to

SAE (P. 171) (SAE 5)

Specification

• Use only oils that comply with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex® products.

Supplier

Motorex®

Racing Fork Oil

Hydraulic fluid (15)

according to

ISOVG(15)

Specification

• Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex® products.

Supplier

Motorex®

Hydraulic Fluid 75

Super unleaded (ROZ 95 / RON 95 / PON 91)

according to

DIN EN 228 (ROZ 95 / RON 95 / PON 91)

Chain cleaner

Specification

• KTM recommends Motorex® products.

Supplier

Motorex®

• Chain Clean 611

Cleaning and polishing materials for metal, rubber and plastic

Specification

• KTM recommends Motorex® products.

Supplier

Motorex®

Protect & Shine 645

Contact spray

Specification

• KTM recommends Motorex® products.

Supplier

Motorex®

Accu Contact

High-luster polish for paint

Specification

• KTM recommends Motorex® products.

Supplier

Motorex®

Moto Polish

Long-life grease

Specification

• KTM recommends Motorex® products.

Supplier

Motorex®

• Long Therm 2000

Motorcycle cleaner

Specification

• KTM recommends Motorex® products.

Supplier

Motorex®

Moto Clean 900

Offroad chain spray

Specification

• KTM recommends Motorex® products.

Supplier

Motorex

Chain Lube 622

Universal oil spray

Specification

• KTM recommends Motorex® products.

Supplier

Motorex®

Joker 440 Universal

JAS0 T903 MA

Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Earlier, 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. With most motorcycles, the gearbox and the clutch are lubricated with the oil as the engine. The JASO MA Standard meets these special requirements.

SAE

The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity. The viscosity describes only one property of oil and says nothing about quality.

A

Air filter

fitting 120

removing 119

Antifreeze

checking 122

B

Baggage 40

Battery

fitting 104

recharging 105

removing 103

Brake discs

checking 75

Brake fluid

adding brake fluid for front brake 78

of rear brake, adding 87

Brake fluid level

Checking the front brake brake fluid level 78

of rear brake, checking 86

Brake linings 80

changing for rear brake 89

Changing the front brake linings 81

of front brake, checking 81

of rear brake, checking 89

Brakes 48

Braking 48

C

Chain

checking dirt 69

checking wear 74

cleaning 69

Chain guide

adjusting 75

Chain tension

adjusting 71

checking 70

Chassis number 16

Checking headlamp setting 118

Cleaning 147-148

Clutch

checking/correcting fluid level 129

Clutch lever 19

adjusting basic position 129

Combination instrument 25

Coolant temperature indicator 32

Display 27

Display ODO 30

DisplayTRIP F 32

Function buttons 25

Indicator lights 26

Settingkilometersormiles 28

Setting the clock 29

Setting/resetting TRIP 1 display 30

Setting/resetting TRIP 2 display 31

Speed display 28

Tachometer 26

Time 29

Conservation for winter operation 149

Coolant

draining 126

Coolant level

checking 122, 124

Cooling system 121

filling 127

D

Display 27

Dust boots

cleaning 63

E

Electric starter button 24

Emergency OFF switch 23

Engine

running in 40

Engine characteristic

adjusting 111

Engine guard

installing 132

removing 132

Engine number 17

Engine oil

changing 133

draining 134

refilling 139

topping up 140

Engine oil level

checking 133

Environment 9

F

Fillercap

closing 33

opening 33

Filling up

Fuel 51

Flasher bulb

changing 117

Flasherswitch 21-22

Flashing code 144-146

Foot brake pedal 36

adjusting basic position 85

checking free play 85

Fork 57

Adjusting compression damping 57

Adjusting rebound 58

Bleeding fork legs 62

Fork part number 18

Fork protector

positioning 64

remove 64

Front wheel

fitting 94

removing 92

Fuel, oils, etc. 8

Fuse

of individual power consumer, changing 109

H

Hand brake lever 19

adjusting free travel 77

checking free play 76

Handlebar angle

adjusting 67

Handlebar position 67

adjusting 68

Handrails 34

Headlight

Adjusting the light range 119

Headlight bulb, changing 115

Headlight flasher switch 21

Headlight mask with headlight

fitting 114

removing 113

Horn 22-23

1

Ignition lock 24

Indicator lights 26

K

Key number 17

L

Light switch 20

Loading the vehicle 40

M

Main fuse

changing 107

Maintenance 8

Motorcycle

cleaning 147

jacking up 56

removing from the work stand 56

0

Oil filter

changing 133

fitting 137

removing 135

Oil screen

cleaning 133

Oil screens

cleaning 137

OWNER'S MANUAL

Basics 10

P

Parking 49

Parking light bulb

changing 116

Passenger footrests 35

Play in gas Bowden cable

adjusting 131

checking 130

Putting into operation

Advice on first use 38

after storage 151

Checks before putting into operation 42

R

Rear hub rubber dampers

checking 97

Rear sprocket / engine sprocket

checking for wear 73

Rear wheel

fitting 96

removing 95

Riding 45

Starting up 45

s

Seat

mounting 103

removing 102

Seat release 34

Shift lever 35

Shifting 45

Shock absorber 57

adjusting rebound damping 62

compression damping, general 59

compression damping, high-speed, adjusting 60

compression damping, low-speed, adjusting 59

Shock absorber part number 18

Side stand 37

Spare parts, accessories 9

Spoke tension

checking 101

Starting 43

Steering head bearing play

adjusting 66

checking 65

Steering lock 24

Stopping 49

Storage 150

T

Tachometer 26

Technical data

Chassis 157-159

Chassis tightening torques 163-165

Engine 152-153

Engine tightening torques 154-156

Fork 160

Shock absorber 161-162

Tire air pressure

checking 100

Tire condition

checking 98

Transport 9

Troubleshooting 141-143

Type label 16

V

View of vehicle

front left 12

rear right side 14

W

Warranty 8

3211239en