300 EXC (2020) - Motorcycle KTM - Free user manual and instructions

USER MANUAL 300 EXC (2020) KTM

Side profile of a KFC motor with visible tire, wheels, and brake calipers (no text or symbols)

Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports vehicle that will continue giving you pleasure for a long time if you maintain it properly.

We wish you good and safe riding at all times!

Enter the serial numbers of your vehicle below.

Vehicle identification number ( p. 13) Dealer's stamp
Engine number ( p. 13)
Key number ( p. 13)

The Owner's Manual contained the latest information for this model series at the time of going to print. However, minor differences due to further developments in design cannot be ruled out completely.

All specifications contained are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt 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 figures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

© 2019 KTM Sportmotorcycle GmbH, Mattighofen Austria

All rights reserved

Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.

REG.NO. 12 100 6061

ISO 9001(12 100 6061)

KTM applies quality assurance processes that lead to the highest possible product quality as defined in the ISO 9001 international quality management standard.

Issued by: TÜV Management Service

KTM Sportmotorcycle GmbH

Stallhofnerstraße 3

5230 Mattighofen, Austria

This document is valid for the following models:

300 EXC BR (F7440T6)

1 MEANS OF REPRESENTATION 6

1.1 Symbols used 6

1.2 Formats used.... 6

2 SAFETY ADVICE.... 7

2.1 Use definition - intended use.... 7

2.2 Misuse.... 7

2.3 Safety advice.... 7

2.4 Degrees of risk and symbols ...... 7

2.5 Tampering warning.... 8

2.6 Safe operation 8

2.7 Protective clothing 9

2.8 Work rules.... 9

2.9 Environment.... 9

2.10 Owner's Manual 9

3 IMPORTANT NOTES.... 10

3.1 Manufacturer and implied warranty.... 10

3.2 Fuel, auxiliary substances.... 10

3.3 Spare parts, accessories 10

3.4 Service 10

3.5 Figures 10

3.6 Customer service.... 10

4 VIEW OF VEHICLE 11

4.1 View of vehicle, front left (example) ... 11

4.2 View of vehicle, rear right (example).... 12

5 SERIAL NUMBERS 13

5.1 Vehicle identification number...... 13

5.2 Type label 13

5.3 Key number.... 13

5.4 Engine number 13

5.5 Fork part number 14

5.6 Shock absorber article number ..... 14

6 CONTROLS.... 15

6.1 Clutch lever.... 15

6.2 Hand brake lever.... 15

6.3 Throttle grip 15

6.4 Switch-off button 15

6.5 Horn button.... 16

6.6 Light switch 16

6.7 Turn signal switch.... 16

6.8 Emergency OFF switch 16

6.9 Start button.... 17

6.10 Overview of indicator lamps 17

6.11 Opening the fuel tank filler cap ..... 17

6.12 Closing the fuel tank filler cap...... 18

6.13 Fuel tap 18

6.14 Choke 19

6.15 Shift lever 19

6.16 Foot brake lever 19

6.17 Side stand.... 20

6.18 Steering lock 20

6.19 Locking the steering.... 20

6.20 Unlocking the steering.... 21

7 COMBINATION INSTRUMENT 22

7.1 Combination instrument overview ..... 22

7.2 Activation and test 22

7.3 Setting the kilometers or miles 22

7.4 Adjusting combination instrument function 23

7.5 Setting the clock.... 24

7.6 Viewing the lap time.... 24

7.7 Display mode SPEED (speed)...... 25

7.8 Display mode SPEED/H (operating hours).... 25

7.9 Setup menu 25

7.10 Adjusting the unit of measurement .... 26

7.11 Display mode SPEED/CLK (time)..... 27

7.12 Setting the clock.... 27

7.13 Display mode SPEED/LAP (lap time) 27

7.14 Viewing the lap time.... 28

7.15 Display mode SPEED/ODO (odometer) 28

7.16 Display mode SPEED/TR1 (trip master 1) 29

7.17 Display mode SPEED/TR2 (trip master 2) 29

7.18 Setting TR2 (trip master 2)...... 29

7.19 Display mode SPEED/A1 (average speed 1) 30

7.20 Display mode SPEED/A2 (average speed 2) 30

7.21 Display mode SPEED/S1 (stop watch 1) 31

7.22 Display mode SPEED/S2 (stop watch 2) 31

7.23 Table of functions 32

7.24 Table of conditions and menu activation 33

8 PREPARING FOR USE 34

8.1 Advice on preparing for first use ..... 34

8.2 Running in the engine 35

8.3 Preparing the vehicle for difficult operating conditions.... 35

8.4 Preparing the vehicle for riding on dry sand.... 36

8.5 Preparing the vehicle for riding on wet sand 37

8.6 Preparing the vehicle for riding on wet and muddy circuits 38

8.7 Preparing vehicle for high temperatures or slow riding 39

8.8 Preparing the vehicle for low temperatures or snow 39

9 RIDING INSTRUCTIONS.... 40

9.1 Checks and maintenance measures when preparing for use 40

9.2 Starting the vehicle 40

9.3 Starting off.... 41

9.4 Shifting, riding 41

9.5 Braking.... 42

9.6 Stopping, parking.... 42

9.7 Transporting.... 43

9.8 Refueling 43

10 SERVICE SCHEDULE 45

10.1 Additional information.... 45

10.2 Required work 45

10.3 Recommended work.... 46

11 TUNING THE CHASSIS 47

11.1 Checking the basic chassis setting with rider's weight.... 47

11.2 Compression damping of the shock absorber.... 47

11.3 Adjusting the low-speed compression damping of the shock absorber.... 47

11.4 Adjusting the high-speed compression damping of the shock absorber.... 48

11.5 Adjusting the rebound damping of the shock absorber.... 49

11.6 Measuring the dimension of the rear wheel unloaded.... 49

11.7 Checking the static sag of the shock absorber.... 50

11.8 Checking the riding sag of the shock absorber.... 50

11.9 Adjusting the spring preload of the shock absorber 51

11.10 Adjusting the riding sag.... 52

11.11 Checking the basic setting of the fork 52

11.12 Adjusting the compression damping of the fork 53

11.13 Adjusting the rebound damping of the fork.... 53

11.14 Handlebar position.... 54

11.15 Adjusting the handlebar position .... 54

12 SERVICE WORK ON THE CHASSIS.... 56

12.1 Raising the motorcycle with a lift stand 56

12.2 Removing the motorcycle from the lift stand 56

12.3 Bleeding the fork legs.... 56

12.4 Cleaning the dust boots of the fork legs 57

12.5 Removing the fork protector 57

12.6 Installing the fork protector.... 58

12.7 Removing the fork legs 58

12.8 Installing the fork legs 59

12.9 Removing the lower triple clamp .... 59

12.10 Installing the lower triple clamp .... 60

12.11 Checking steering head bearing play 62

12.12 Adjusting the steering head bearing play 63

12.13 Lubricating the steering head bearing 64

12.14 Removing front fender 64

12.15 Installing front fender.... 64

12.16 Removing the shock absorber...... 65

12.17 Installing the shock absorber ..... 65

12.18 Removing the seat 66

12.19 Mounting the seat 66

12.20 Removing the air filter box cover ..... 67

12.21 Installing the air filter box cover ..... 67

12.22 Removing the air filter 68

12.23 Installing the air filter 68

12.24 Cleaning the air filter and air filter box 69

12.25 Preparing air filter box cover for securing 69

12.26 Removing the main silencer 70

12.27 Installing the main silencer.... 70

12.28 Changing the glass fiber yarn filling in the main silencer....70

12.29 Removing the fuel tank 71

12.30 Installing the fuel tank 72

12.31 Checking the chain for dirt.... 73

12.32 Cleaning the chain 74

12.33 Checking the chain tension 74

12.34 Adjusting the chain tension.... 75

12.35 Checking the chain, rear sprocket, engine sprocket, and chain guide ..... 76

12.36 Checking the frame 79

12.37 Checking the link fork 79

12.38 Checking throttle cable routing..... 79

12.39 Checking the rubber grip 80

12.40 Adjusting the basic position of the clutch lever 81

12.41 Checking/correcting the fluid level of the hydraulic clutch 81

12.42 Changing the hydraulic clutch fluid 82

13 BRAKE SYSTEM 84

13.1 Checking the free travel of the hand brake lever 84

13.2 Adjusting the free travel of the handbrake lever 84

13.3 Checking the brake discs 84

13.4 Checking the front brake fluid level ... 85

13.5 Adding front brake fluid 86

13.6 Checking the front brake linings ..... 87

13.7 Changing the brake linings of the front brake 87

13.8 Checking the free travel of foot brake lever 90

13.9 Adjusting the basic position of the foot brake lever 90

13.10 Checking the rear brake fluid level..... 91

13.11 Adding rear brake fluid.... 91

13.12 Checking the brake linings of the rear brake.... 93

13.13 Changing the brake linings of the rear brake 93

14 WHEELS, TIRES 96

14.1 Removing the front wheel 96

14.2 Installing the front wheel 97

14.3 Removing the rear wheel 97

14.4 Installing the rear wheel 98

14.5 Checking the tire condition 100

14.6 Checking tire pressure 100

14.7 Checking spoke tension 101

15 ELECTRICAL SYSTEM 102

15.1 Removing the 12-V battery ..... 102

15.2 Installing the 12-V battery ..... 103

15.3 Charging the 12-V battery ..... 103

15.4 Changing the main fuse.... 105

15.5 Removing the headlight mask with the headlight 106

15.6 Installing the headlight mask with the headlight 106

15.7 Changing the headlight bulb ..... 107

15.8 Changing the turn signal bulb ..... 107

15.9 Checking the headlight setting ..... 108

15.10 Adjusting the headlight range..... 109

15.11 Changing the combination instrument battery.... 109

16 COOLING SYSTEM 111

16.1 Cooling system 111

16.2 Checking the antifreeze and coolant level.... 111

16.3 Checking the coolant level 112

16.4 Draining the coolant 112

16.5 Refilling with coolant 113

17 TUNING THE ENGINE.... 115

17.1 Checking the throttle cable play ..... 115

17.2 Adjusting the throttle cable play 115

17.3 Carburetor tuning.... 116

17.4 Carburettor - idle speed.... 119

17.5 Carburetor - adjusting the idle speed 119

17.6 Ignition curve plug-in connector ..... 120

17.7 Changing the ignition timing map .... 120

17.8 Checking the basic position of the shift lever.... 121

17.9 Adjusting the basic position of the shift lever 121

17.10 Engine characteristic - auxiliary spring 122

17.11 Engine characteristic - adjusting the auxiliary spring 122

18 SERVICE WORK ON THE ENGINE 124

18.1 Emptying the carburetor float chamber 124

18.2 Checking the gear oil level 125

18.3 Changing the gear oil 125

18.4 Adding the gear oil 126

19 CLEANING, CARE 128

19.1 Cleaning the motorcycle 128

19.2 Checks and maintenance steps for winter operation.... 129

20 STORAGE.... 130

20.1 Storage 130

20.2 Preparing for use after storage...... 131

21 TROUBLESHOOTING 132

22 TECHNICAL DATA.... 134

22.1 Engine 134

22.2 Engine tightening torques 134

22.3 Carburetor.... 137

22.3.1 Carburetor tuning 137

22.4 Capacities 138

22.4.1 Gear oil.... 138

22.4.2 Coolant.... 138

22.4.3 Fuel 138

22.5 Chassis 138

22.6 Electrical system.... 139

22.7 Tires.... 139

22.8 Fork.... 139

22.9 Shock absorber.... 140

22.10 Chassis tightening torques 140

23 SUBSTANCES 143

24 AUXILIARY SUBSTANCES 145

25 STANDARDS 147

26 LIST OF ABBREVIATIONS.... 148

TABLE OF CONTENTS

27 LIST OF SYMBOLS.... 149

27.1 Yellow and orange symbols.... 149
27.2 Green and blue symbols.... 149

INDEX 150

1 MEANS OF REPRESENTATION

1.1 Symbols used

The meaning of specific symbols is described below.

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

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

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

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

Indicates information with more details or tips.

Indicates the result of a testing step.

Indicates a voltage measurement.

Indicates a current measurement.

Indicates the end of an activity, including potential rework.

1.2 Formats used

The typographical formats used in this document are explained below.

Proprietary name Indicates a proprietary name.

Name®

Indicates a protected name.

Brand™ Indicates a brand available on the open market.

Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained in the glossary.

2.1 Use definition - intended use

This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations.

Info

This vehicle is only authorized for operation on public roads in the homologated (restricted) version.

The derestricted version of this vehicle must only be operated in closed off areas away from public highway traffic.

This vehicle is designed for use in offroad endurance competition, and not primarily for use in motocross.

2.2 Misuse

The vehicle must only be used as intended.

Dangers can arise for people, property and the environment through use not as intended.

Any use of the vehicle beyond the intended and defined use constitutes misuse.

Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respective use.

2.3 Safety advice

A number of safety instructions need to be followed to operate the product described safely. Therefore read this instruction and all further instructions included carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages.

Info

Various information and warning labels are attached in prominent locations on the product described. Do not remove any information or warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured.

2.4 Degrees of risk and symbols

Danger

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.

Warning

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Caution

Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

Note

Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Note

Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.

2.5 Tampering warning

Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:

1 The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

1 Removal or puncturing of the main silencers, baffles, header pipes or any other components which conduct exhaust gases.
2 Removal or puncturing of parts of the intake system.
3 Lack of proper maintenance.
4 Replacing moving parts of the vehicle, or parts of the exhaust system or intake system, with parts other than those specified by the manufacturer.

2.6 Safe operation

Danger

Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.

• Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
• Do not operate the vehicle if you are physically or mentally impaired.

Danger

Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

• Always make sure there is sufficient ventilation when running the engine.
• Use effective exhaust extraction when starting or running the engine in an enclosed space.

Warning

Danger of burns Some vehicle components become very hot when the vehicle is operated.

• Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have cooled down.
• Let the vehicle parts cool down before you perform any work on the vehicle.

Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner.

The vehicle should only be used by trained persons. An appropriate driver's license is needed to drive the vehicle on public roads.

Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.

Adhere to the information and warning labels on the vehicle.

2.7 Protective clothing

Warning

Risk of injury Missing or poor protective clothing presents an increased safety risk.

• Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides.
• Always wear protective clothing that is in good condition and meets the legal regulations.

In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.

2.8 Work rules

Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered using the number in parentheses. Example: bearing puller (15112017000)

During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts, seals, sealing rings, O-rings, pins, and lock washers).

In the case of certain screws, a screw adhesive (e.g. Euciterequired. Observe the manufacturer's instructions.

If thread locker (e.g., Precote) has already been applied to a new part, do not apply any additional thread locker. After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.

After completing a repair or service work, check the operating safety of the vehicle.

2.9 Environment

If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.

When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the respective country.

Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.

2.10 Owner's Manual

It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains useful information and many tips on how to operate, handle, and service your motorcycle. Only then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury.

Keep the Owner's Manual in an accessible place to enable you to refer to it as needed.

If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.

The Owner's Manual is an important component of the vehicle and must be handed over to the new owner if the vehicle is sold.

The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. International KTM Website: http://www.ktm.com

3.1 Manufacturer and implied warranty

The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and confirmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

3.2 Fuel, auxiliary substances

Note

Environmental hazard Improper handling of fuel is a danger to the environment.

- Do not allow fuel to enter the groundwater, the soil, or the sewage system.

Use fuels and auxiliary substances in accordance with the Owner's Manual and specification.

3.3 Spare parts, accessories

For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.

Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized KTM dealer will be glad to advise you.

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

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

3.4 Service

A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the engine and chassis is properly carried out as described in the Owner's Manual. An incorrect suspension setting can lead to damage and breakage of chassis components.

Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can result in significantly increased wear of components, such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.

It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle.

The relevant mileage or time interval is whichever occurs first.

3.5 Figures

The figures contained in the manual may depict special equipment.

In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text.

3.6 Customer service

Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.

A list of authorized KTM dealers can be found on the KTM website.

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

4.1 View of vehicle, front left (example)

① ② ③ ④ ⑤ ⑥ ⑦ ⑧ S03662-10

1 Hand brake lever (p. 15)
② Light switch (p. 16)
② Switch-off button (p. 15)
② Turn signal switch ( p. 16)
② Horn button ( p. 16)
③ Clutch lever (p. 15)
4 Chain guide
5 Air filter box cover
6 Side stand ( p. 20)
7 Shift lever ( p. 19)
8 Fuel tap (p. 18)

4 VIEW OF VEHICLE

4.2 View of vehicle, rear right (example)

① ② ③ ⑥ ⑤ ④ S03661-10

① Fuel tank filler cap
② Throttle grip (p. 15)
③ Vehicle identification number ( p. 13)
5 Foot brake lever ( p. 19)
6 Level viewer for brake fluid, rear

5.1 Vehicle identification number

1 401945-10

The vehicle identification number ^1 is stamped on the right side of the steering head.

5.2 Type label

① 401946-10

Type label 1 is fixed to the front of the steering head.

5.3 Key number

1234567 1 402247-10

The key number 1 for the steering lock is stamped onto the key connector.

5.4 Engine number

① H01047-10

The engine number 1 is located on the left side of the engine over the engine sprocket.

5 SERIAL NUMBERS

5.5 Fork part number

401947-10

The fork part number① is stamped on the inside of the axle clamp.

5.6 Shock absorber article number

H02222-10

Shock absorber article number ^1 is stamped on the top of the shock absorber above the adjusting ring towards the engine side.

6.1 Clutch lever

Close-up of a mechanical component with labeled part (1) and reference number S03609-10, no readable text or symbols beyond labels

Clutch lever 1 is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automatically.

6.2 Hand brake lever

Close-up of a mechanical component with labeled parts (1), no readable text or symbols beyond the label and reference number S03610-10

Hand brake lever ^1 is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever.

6.3 Throttle grip

Close-up of a mechanical grip with a textured handle and labeled component (no readable text or symbols)

Throttle grip ① is fitted on the right side of the handlebar.

6.4 Switch-off button

Close-up of a black brake lever handle with adjustment knob and control buttons (no readable text or symbols)

Switch-off button 1 is fitted on the left side of the handlebar.

Possible states

• The switch-off button is in the basic position – In this position, the ignition circuit is closed and the engine can be started.
• The switch-off button is pressed – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.

6.5 Horn button

Close-up of a black brake switch handle with a numbered component (1) and no visible text or symbols on the device itself.

Horn button 1 is fitted on the left side of the handlebar.

Info

The horn button has no function when the vehicle is delivered.

Possible states

• The horn button is in the basic position
- The horn button is pressed – The horn is operated in this position.

6.6 Light switch

Close-up of a mechanical device's grip and lever assembly (no visible text or symbols)

Light switch① is fitted on the left side of the handlebar.

Possible states

	Low beam on – Light switch is in the central position. In this position, the low beam and tail light are switched on.
	High beam on – Light switch is turned to the left. In this position, the high beam and the tail light are switched on.

6.7 Turn signal switch

Close-up of a black brake lever handle and grip mechanism (no visible text or symbols)

Turn signal switch1 is fitted on the left side of the handlebar.

Possible states

	Turn signal off – The turn signal switch is in the central position.
	Left turn signal, on – The turn signal switch is turned to the left.
	Right turn signal, on – The turn signal switch is turned to the right.

6.8 Emergency OFF switch

Close-up of a mechanical device with a numbered component (1) and no visible text or symbols on the main body.

The emergency OFF switch① is fitted on the right side of the handlebar.

Possible states

	Ignition off - In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.
	Ignition on - In this position, the ignition circuit i closed, and the engine can be started.

6.9 Start button

Close-up of a bicycle brake lever with adjustment knob and grip (no visible text or symbols)

Start button 1 is fitted on the right side of the handlebar.

Possible states

• The start button is in the basic position
• The start button is pressed – In this position, the starter motor is actuated.

6.10 Overview of indicator lamps

Close-up of a car's front dashboard and steering wheel (no visible text or symbols)

Possible states

	The high beam indicator lamp lights up blue - The high beam is switched on.
	Malfunction indicator lamp - inoperative
	Fuel level warning lamp - inoperative
	Turn signal indicator lamp flashes green - The turn signal is switched on.

6.11 Opening the fuel tank filler cap

Danger

Fire hazard Fuel is highly flammable.

The fuel in the fuel tank expands when warm and can escape if overfilled.

• Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
• Switch off the engine for refueling.
• Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
• If any fuel is spilled, wipe it off immediately.
• Observe the specifications for refueling.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

• Avoid skin, eye and clothing contact with fuel.
• Immediately consult a doctor if you swallow fuel.
• Do not inhale fuel vapors.
• In case of skin contact, rinse the affected area with plenty of water.
• Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
• Change your clothing in case of fuel spills on them.
• Keep fuels correctly in a suitable canister, and out of the reach of children.

Note

Environmental hazard Improper handling of fuel is a danger to the environment.

- Do not allow fuel to enter the groundwater, the soil, or the sewage system.

Close-up of a motorcycle seatbelt with a numbered component (1) pointing to the seat area, no visible text or symbols on the device itself.

- Press release button①, turn the fuel tank filler cap counterclockwise, and lift it off.

6.12 Closing the fuel tank filler cap

① ② S03647-11

- Mount the fuel tank filler cap and turn it clockwise until release button ① engages.

Info

Route fuel tank breather hos ^2 without kinks.

6.13 Fuel tap

1 RES OFF ON K01202-10

The fuel tap is on the left side of the fuel tank.

Open or close the fuel supply to the carburetor using tap handle ① on the fuel tap.

Possible states

• Fuel supply closed OFF – Fuel cannot flow from the fuel tank to the carburetor.
• Open fuel supply ON – Fuel can flow from the fuel tank to the carburetor. The fuel tank empties down to the reserve level.
• Fuel reserve supply open RES – Fuel can flow from the fuel tank to the carburetor. The fuel tank empties completely.

6.14 Choke

Close-up of a mechanical assembly with visible components and a numbered label (1), no readable text or symbols present.

Choke 1 is fitted on the left side of the carburetor. Activating the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel. This results in a richer fuel-air mixture, which is needed for a cold start.

Info

If the engine is warm, the choke function must be deactivated.

Possible states

• Choke function activated – The choke lever is pulled out to the stop.
• Choke function deactivated – The choke lever is pushed in to the stop.

6.15 Shift lever

Pure mechanical diagram showing a gear and linkage without any text, numbers, or symbols

Shift lever① is mounted on the left side of the engine.

2 3 4 5 6 N 1 401950-11

The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears.

6.16 Foot brake lever

1 401956-10

Foot brake lever ^① is located in front of the right footrest. The foot brake lever is used to activate the rear brake.

6.17 Side stand

Line drawing of a motorcycle with labeled parts (no text or symbols on the diagram itself)

The side stand ^1 is located on the left of the vehicle.

① ② 401944-10

The side stand is used for parking the motorcycle.

Info

When you are riding, side star ^1 must be folded up and secured with rubber stra ^2 .

6.18 Steering lock

Close-up of a mechanical component with numbered annotation (1) and V00328-10 label, no readable text or symbols beyond the label.

Steering lock ^① is fitted on the left side of the steering head. The steering lock is used to lock the steering. Steering, and therefore riding, is no longer possible.

6.19 Locking the steering

Note

Danger of damage The parked vehicle can roll away or fall over.

- Park the vehicle on a firm and level surface.

Simple black padlock icon on white background (no text or symbols)

• Park the vehicle.
• Turn handlebar as far as possible to the right.
• Insert the key for the steering lock into the steering lock, turn it to the left, press it in, and turn it to the right. Pull out the key for the steering lock.

√ Steering is no longer possible.

Info

Never leave the key for the steering lock in the steering lock.

6.20 Unlocking the steering

Simple black padlock icon on white background, no text or symbols present

- Insert the key for the steering lock into the steering lock, turn it to the left, pull it out, and turn it to the right. Pull out the key for the steering lock.

√ The handlebar can now be moved again.

Info

Never leave the key for the steering lock in the steering lock.

7 COMBINATION INSTRUMENT

7.1 Combination instrument overview

Line drawing of a remote control device with buttons and display (no text or symbols)

• Press the button to control different functions.
• Press the button-to control different functions.

Info

When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.

7.2 Activation and test

LAP 888.8 TR1 TR2 A1 A2 S1 S2 TR2 88:88:88 SPEED WS Km/h Mph Miles ODO LAP CLK H 400313-01

Activating combination instrument

The combination instrument is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor.

Display test

To enable you to check that the display is functioning properly, all display segments light up briefly.

2205 WS 400314-01

WS (wheel size)

After the display function check, the wheel circumference WS is displayed briefly.

Info

The number 2205 equals the circumference of the 21" front wheel with standard tires.

The display then changes to the last selected mode.

7.3 Setting the kilometers or miles

Info

If you change the unit, the value ODO is retained and converted accordingly. The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed.

TR1 TR2 A1 A2 S1 S2 ≥ Km/h Mph ≤ ODO LAP CLK H 400329-01

Condition

The motorcycle is stationary.

• Repeatedly press the button briefly until H appears at the bottom right of the display.
• Press the button for 2–3 seconds.
  √ The Setup menu is displayed and the active functions are shown.
• Repeatedly press the button + briefly until Km/h/Mph flashes.

Adjusting the Km/h

- Press the button+.

Adjusting the Mph

- Press the button.

- Wait 3 - 5 seconds.

√ The settings are stored.

Info

If no button is pressed for 10–12 seconds, or if an impulse comes from the wheel speed sensor, the settings are automatically saved and the setup menu is closed.

7.4 Adjusting combination instrument function

Info

When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.

≥TR1≤TR2 A1 A2 S1 S2 Km/h Mph ODO LAP CLK H 400318-01

Condition

The motorcycle is stationary.

• Repeatedly press the button+briefly until H appears at the bottom right of the display.
• Press the button for 2–3 seconds.

√ The Setup menu is displayed and the active functions are shown.

Info

If no button is pressed for 10–12 seconds, the settings are automatically saved.

If no button is pressed for 20 seconds, or if an impulse comes from the wheel speed sensor, the settings are automatically saved and the setup menu is closed.

- Repeatedly press the button briefly until the desired function flashes.

√ The selected function flashes.

Activating the function

- Press the button+.

√ The symbol continues to appear in the display and the next function appears.

Deactivating a function

- Press the button—.

√ The symbol disappears in the display and the next function appears.

7.5 Setting the clock

0-24 18:32:47 CLK 400330-01

Condition

The motorcycle is stationary.

• Repeatedly press the button-briefly until CLK appears at the bottom right of the display.
• Press the button for 2–3 seconds.
  √ The hour display flashes.
• Adjust hour display with the button and/or button.
• Wait 3 - 5 seconds.
  √ The next segment of the display flashes and can be set.
• You can set the following segments in the same way as the hours by pressing the button and the button.

Info

The seconds can only be set to zero.

If no button is pressed for 15–20 seconds, or if an impulse comes from the wheel speed sensor, the settings are automatically saved and the setup menu is closed.

7.6 Viewing the lap time

Info

This function can only be opened if lap times have actually been timed.

LAP 1 | 00:08:39 LAP 400321-01

Condition

The motorcycle is stationary.

• Repeatedly press the button briefly until LAP appears at the bottom right of the display.
• Briefly press the button+.
  √ LAP 1 appears on the left side of the display.
• The laps 1 - 10 can be viewed with the button .
• Press and hold the button for 3 - 5 seconds.
  √ The lap times are deleted.
• Briefly press the button+.
  √ Next display mode

Info

When an impulse is received from the wheel speed sensor, the left side of the display changes back to the SPEED mode.

7.7 Display mode SPEED (speed)

SPEED 64 Km/h 00638 000 400317-02

- Repeatedly press the button briefly until SPEED appears on the left side of the display.

The current speed is displayed in the SPEED display mode.

The current speed can be displayed in Km/h or Mph.

Info

Make the setting according to the country.

When an impulse comes from the front wheel, the left side of the display changes to the SPEED mode and the current speed is shown.

7.8 Display mode SPEED/H (operating hours)

SPEED 0 Km/h | 00:06:3 H 400316-01

Condition

• The motorcycle is stationary.
- Repeatedly press the button briefly until H appears at the bottom right of the display.

In display mode H, the operating hours of the engine are displayed.

The operating hour counter stores the total traveling time.

Info

The operating hour counter is necessary for ensuring that service work is carried out at the right intervals.

If the combination instrument is in H display mode when starting off, it automatically changes to the ODO display mode.

The H display mode is suppressed during the journey.

Press the button for 2–3 seconds.	The display changes to the setup menu for the combination instrument functions.
Briefly press the button+.	Next display mode
Press the button for 2–3 seconds.	No function
Briefly press the button-.	No function

7.9 Setup menu

TR1 TR2 A1 A2 S1 S2 Km/h Mph ODO LAP CLK H 400344-01

Condition

• The motorcycle is stationary.
• Repeatedly press the button briefly until H appears at the bottom right of the display.
• Press the button for 2–3 seconds.

The Setup menu displays the active functions.

7 COMBINATION INSTRUMENT

Info

Repeatedly press the button briefly until the desired function is reached.

If no button is pressed for 20 seconds, the settings are automatically saved.

Briefly press the button. +	Activates the flashing display and changes to the next display
Press the button for 2-3 seconds.	No function
Briefly press the button. -	Deactivates the flashing display and changes to the next display
Press the button for 2-3 seconds.	No function
Wait 3 - 5 seconds.	Changes to the next display without changes
Wait 10 - 12 seconds.	Setup menu starts, stores the settings, and changes to H or ODO.

7.10 Adjusting the unit of measurement

TR1 TR2 A1 A2 S1 S2 Km/h Mph CDO LAP CLK H 400329-01

Condition

• The motorcycle is stationary.
- Repeatedly press the button briefly until H appears at the bottom right of the display.
- Press the button for 2–3 seconds.
- Repeatedly press the button briefly until Km/h/Mph flashes.
In measurement unit mode, you can change the unit of measurement.

Info

If no button is pressed for 5 seconds, the settings are automatically saved.

Briefly press the button.	Starts selection, activates Km/h display
Press the button for 2-3 seconds.	No function
Briefly press the button.	ActivatesMphdisplay
Press the button for 2-3 seconds.	No function
Wait 3 - 5 seconds.	Changes to the next display, changes from selection to the Setup menu
Wait 10 - 12 seconds.	Stores and closes the Setup menu

7.11 Display mode SPEED/CLK (time)

SPEED 68 Km/h 12:08:54 CLK 400319-01

- Repeatedly press the button briefly until CLK appears at the bottom right of the display.

The time is shown in display mode CLK.

Press the button for 2-3 seconds.	The display changes to the Setup menu of the clock.
Briefly press the button+.	Next display mode
Press the button for 2-3 seconds.	No function
Briefly press the button-.	No function

7.12 Setting the clock

SPEED 68 Km/h 12:08:54 CLK 400319-01

Condition

• The motorcycle is stationary.
- Repeatedly press the button briefly until CLK appears at the bottom right of the display.
- Press the button for 2–3 seconds.

Press the button for 2-3 seconds.	Increases the value
Briefly press the button+	Increases the value
Press the button for 2-3 seconds.	Reduces the value
Briefly press the button-	Reduces the value
Wait 3 - 5 seconds.	Changes to the next value
Wait 10 - 12 seconds.	Closes the SETUP menu

7.13 Display mode SPEED/LAP (lap time)

SPEED 27 Km/h 00:08:39 LAP 400320-01

- Repeatedly press the button briefly until LAP appears at the bottom right of the display.

In the LAP display mode, up to 10 lap times can be timed with the stop watch.

Info

If the lap time continues running after the button is pressed, 9 memory locations are occupied.

Lap 10 must be timed using the button.

7 COMBINATION INSTRUMENT

Press the button for 2-3 seconds.	The stop watch and the lap time are reset.
Briefly press the button+.	Next display mode
Press the button for 2-3 seconds.	Stops the clock.
Briefly press the button-.	Starts the stop watch or stop the current lap time measurement, stores it and the stop wat starts the next lap.

7.14 Viewing the lap time

LAP 1 | 00:08:39 LAP 400321-01

Condition

• The motorcycle is stationary.
- Repeatedly press the button-briefly until LAP appears at the bottom right of the display.
- Briefly press the button+.

Press the button for 2-3 seconds.	The stop watch and the lap time are reset.
Briefly press the button+	Select a lap from 1-10
Press the button for 2-3 seconds.	No function
Briefly press the button-.	View the next lap time.

7.15 Display mode SPEED/ODO (odometer)

SPEED 64 Km/h 00638 CDO 400317-01

• Repeatedly press the button briefly until ODO appears at the bottom right of the display.
  The total traveled distance is shown in display mode ODO.

Press the button for 2-3 seconds.	No function
Briefly press the button+	Next display mode
Press the button for 2-3 seconds.	No function
Briefly press the button-.	No function

7.16 Display mode SPEED/TR1 (trip master 1)

SPEED 65 Km/h TR1 129.3 400323-01

- Repeatedly press the button briefly until TR1 appears at the top right of the display.

TR1 (trip master 1) runs constantly and counts up to 999.9. You can use it to measure trips or the distance between refueling stops.

TR1 is coupled with A1 (average speed 1) and S1 (stop watch 1).

Info

If 999.9 is exceeded, the values of TR1, A1 and S1 are automatically reset to 0.0.

Press the button for 2–3 seconds.	Displays of TR1, A1 and S1 are reset to 0,0.
Briefly press the button+.	Next display mode
Press the button for 2–3 seconds.	No function
Briefly press the button-.	No function

7.17 Display mode SPEED/TR2 (trip master 2)

SPEED 62 Km/h TR2 38.4 400324-01

- Repeatedly press the button briefly until TR2 appears at the top right of the display.

TR2 (trip master 2) runs constantly and counts up to 999.9.

Press the button for 2–3 seconds.	Clears the values TR2 and A2.
Briefly press the button+.	Next display mode
Press the button for 2–3 seconds.	Reduces value of TR2.
Briefly press the button-.	Reduces value of TR2.

7.18 Setting TR2 (trip master 2)

SPEED 62 Km/h TR2 38.4 400324-01

Condition

• The motorcycle is stationary.
• Repeatedly press the button-briefly until TR2 appears at the top right of the display.
• Press the button — for 2–3 seconds until TR2 flashes.

The displayed value can be set manually with the button and the button. This is a very practical function when riding using the road book.

7 COMBINATION INSTRUMENT

Info

The TR2 value can also be corrected manually during the journey with the button and the button. If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0.

Press the button for 2-3 seconds.	Increases value of TR2.
Briefly press the button+	Increases value of TR2.
Press the button for 2-3 seconds.	Reduces value of TR2.
Briefly press the button-.	Reduces value of TR2.
Wait 10 - 12 seconds.	Stores and closes the Setup menu.

7.19 Display mode SPEED/A1 (average speed 1)

SPEED 37 | A1 Km/h 22.9 400325-01

- Repeatedly press the button+briefly until A1 appears at the top right of the display.

A1 (average speed 1) shows the average speed calculated using TR1 (trip master 1) and S1 (stop watch 1).

The calculation of this value is activated by the first impulse of the wheel speed sensor and ends 3 seconds after the last impulse.

Press the button for 2-3 seconds.	Displays of TR1, A1 and S1 are reset to 0.0.
Briefly press the button+	Next display mode
Press the button for 2-3 seconds.	No function
Briefly press the button-.	No function

7.20 Display mode SPEED/A2 (average speed 2)

SPEED 52 Km/h | A2 41.4 400326-01

- Repeatedly press the button+briefly until A2 appears at the top right of the display.

A2 (average speed 2) shows the average speed on the basis of the current speed if the stop watch S2 (stop watch 2) is running.

Info

The displayed value can differ from the actual average speed if S2 was not stopped after the ride.

Briefly press the button+	Next display mode
Press the button for 2–3 seconds.	No function
Press the button for 2–3 seconds.	No function
Briefly press the button—.	No function

7.21 Display mode SPEED/S1 (stop watch 1)

SPEED 31 | 00:18:52 S1 400327-01

- Repeatedly press the button briefly until S1 appears at the top right of the display.

S1 (Stop watch 1) shows the riding time based on TR1 and continues running as soon as an impulse arrives from the wheel speed sensor.

The calculation of this value starts with the first impulse from the wheel speed sensor and ends 3 seconds after the last impulse.

Press the button for 2-3 seconds.	Displays of TR1, A1 and S1 are reset to 0.0.
Briefly press the button.	Next display mode
Press the button for 2-3 seconds.	No function
Briefly press the button.	No function

7.22 Display mode SPEED/S2 (stop watch 2)

SPEED 36 Km/h | 00:06:17 S2 400328-01

- Repeatedly press the button-briefly until S2 appears at the top right of the display.

S2 (Stop watch 2) is a manual stop watch.

If S2 is running in the background, the display S2 flashes.

Press the button for 2-3 seconds.	The displays of S2 and A2 are set to 0,0.
Briefly press the button+	Next display mode
Press the button for 2-3 seconds.	No function
Briefly press the button-.	Starts or stops S2.

7 COMBINATION INSTRUMENT

7.23 Table of functions

Display Press the button for 2-3 seconds.	Briefly press the button.	Press the button for 2-3 seconds.	Briefly press the button.	Wait 3 - 5 seconds.	Wait 10 - 12 seconds.
Display mode SPEED/H (operating hours)	The display changes to the setup menu for the combination instrument functions.	Next display mode	No function No function
Setup menu No	function Activates the flashing display and changes to the next display	No function Deactivates the flashing display and changes to the next display	Changes to the next display without changes	Setup menu starts, stores the settings, and changes to H or ODO.
Adjusting the unit of measurement	No function Starts selection, activates Km/h display	No function Activates Mph display	Changes to the next display, changes from selection to the Setup menu	Stores and closes the Setup menu
Display mode SPEED/CLK (time)	The display changes to the Setup menu of the clock.	No function No function
Setting the clock	Increases the value	Increases the value	Reduces the value	Changes to the next value	Closes the SETUP menu
Display mode SPEED/LAP (lap time)	The stop watch and the lap time are reset.	Next display mode	Stops the clock.	Starts the stop watch or stop the current lap time measurement, stores it and the stop watch starts the next lap.
Viewing the lap time	The stop watch and the lap time are reset.	Select a lap from 1-10	No function View the next lap time.
Display mode SPEED/ODO (odometer)	No function Next display mode	No function No function
Display mode SPEED/TR1 (trip master 1)	Displays of TR1, A1 and S1 are reset to 0,0.	Next display mode	No function No function

Display Press the	button for 2–3 seconds.	Briefly press the button+.	Press the button for 2–3 seconds.	Briefly press the button-.	Wait 3 - 5 seconds.	Wait 10 - 12 seconds.
Display mode SPEED/TR2 (trip master 2)	Clears the values TR2 and A2.	Next display mode	Reduces value of TR2.	Reduces value of TR2.
Setting TR2 (trip master 2)	Increases value of TR2.	Increases value of TR2.	Reduces value of TR2.	Reduces value of TR2.		Stores and closes the Setup menu.
Display mode SPEED/A1 (average speed 1)	Displays of TR1, A1 and S1 are reset to 0.0.	Next display mode	No function No function
Display mode SPEED/A2 (average speed 2)	No function Next display mode		No function No function
Display mode SPEED/S1 (stop watch 1)	Displays of TR1, A1 and S1 are reset to 0.0.	Next display mode	No function No function
Display mode SPEED/S2 (stop watch 2)	The displays of S2 and A2 are set to 0.0.	Next display mode	No function Starts or stops S2.

7.24 Table of conditions and menu activation

Display The motorcycle is	stationary.	Menu can be activated
Display mode SPEED/H (operating hours) •
Setup menu •
Adjusting the unit of measurement •
Setting the clock	•
Display mode SPEED/LAP (lap time)		•
Viewing the lap time	•
Display mode SPEED/TR1 (trip master 1)		•
Display mode SPEED/TR2 (trip master 2)		•
Setting TR2 (trip master 2)	•
Display mode SPEED/A1 (average speed 1)		•
Display mode SPEED/A2 (average speed 2)		•
Display mode SPEED/S1 (stop watch 1)		•
Display mode SPEED/S2 (stop watch 2)		•

8.1 Advice on preparing for first use

Danger

Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.

• Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
• Do not operate the vehicle if you are physically or mentally impaired.

Warning

Risk of injury Missing or poor protective clothing presents an increased safety risk.

• Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides.
• Always wear protective clothing that is in good condition and meets the legal regulations.

Warning

Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling characteristic.

Different tire tread patterns can make the vehicle significantly more difficult to control.

- Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.

Warning

Danger of accidents An unadapted riding style impairs the handling characteristic.

- Adapt your riding speed to the road conditions and your riding ability.

Warning

Danger of accidents The vehicle is not designed to carry passengers.

- Do not ride with a passenger.

Warning

Danger of accidents The brake system fails in the event of overheating.

If the foot brake lever is not released, the brake linings drag continuously.

- Take your foot off the foot brake lever when you are not braking.

Warning

Danger of accidents Total weight and axle loads influence the handling characteristic.

- Do not exceed the maximum permissible overall weight or the axle loads.

Warning

Risk of misappropriation People who act without authorization endanger themselves and others.

- Do not leave the vehicle unattended if the engine is running.

- Protect the vehicle against access by unauthorized persons.

Info

When using your motorcycle, remember that others may feel disturbed by excessive noise.

• Make sure that the pre-sales inspection work has been carried out by an authorized KTM workshop.
  √ You will receive a delivery certificate when the vehicle is handed over.
• Before riding for the first time, read the entire Owner's Manual carefully.
• Get to know the controls.
• Adjust the basic position of the clutch lever. (p. 81)

• Adjust the free travel of the handbrake lever. (p. 84)

• Adjust the basic position of the foot brake lever. (p. 90)

• Adjust the basic position of the shift lever. (p. 121)
• Get used to handling the motorcycle on a suitable surface before undertaking a more challenging trip.

Info

When offroad, it is recommended that you are accompanied by another person on another vehicle so that you can help each other.

– Try also to ride as slowly as possible and in a standing position to get a better feel for the motorcycle.
- Do not make any off-road trips that exceed your ability and experience.
- Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
- If you carry luggage, make sure you secure it firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels.

Info

Motorcycles react sensitively to any changes of weight distribution.

- The maximum permissible overall weight and the maximum permissible axle loads must not be exceeded. Guideline

Maximum permissible overall weight 335 kg (739 lb.)

Maximum permissible front axle load 145 kg (320 lb.)

Maximum permissible rear axle load 190 kg (419 lb.)

- Check the spoke tension. (p. 101)

Info

The spoke tension must be checked after half an hour of operation.

- Run in the engine. (p. 35)

8.2 Running in the engine

- During the running-in phase, do not exceed the specified engine performance. Guideline

Maximum engine performance
During the first 3 operating hours < 70 %
During the first 5 operating hours < 100 %

- Avoid fully opening the throttle!

8.3 Preparing the vehicle for difficult operating conditions

Info

Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can result in significantly increased wear of components, such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.

- Clean the air filter and air filter box. (p. 69)

Info

Check the air filter approx. every 30 minutes.

- Check the electrical connector for humidity and corrosion and to ensure it is firmly seated.

8 PREPARING FOR USE

» If humidity, corrosion, or damage is found:

- Clean and dry the connector, or change it if necessary.

Difficult operating conditions are:

• Rides on dry sand. (p. 36)
• Rides on wet sand. (p. 37)
• Rides on wet and muddy circuits. (p. 38)
• Rides at high temperatures or slow riding. (p. 39)
• Riding at low temperatures and in snow. ( p. 39)

8.4 Preparing the vehicle for riding on dry sand

1,8 M01129-01

- Check the radiator cap.

Value on the radiator cap 1.8 bar (26 psi)

» If the indicated value does not correspond to the setpoint value:

Warning

Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.

• Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
• Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
• In the event of scalding, rinse the area affected immediately with lukewarm water.

- Change the radiator cap.

- Mount the air filter dust cover.

Air filter dust cover (79006920000)

TwinAir SURFACE M01104-01

Info

Observe the KTM PowerParts fitting instructions.

Close-up of a transparent plastic bag with 'Twin Air' branding, no visible text or symbols on the bag itself.

- Mount the air filter sand cover.

Air filter sand cover (79006922000)

Info

Observe the KTM PowerParts fitting instructions.

- Adjust the carburetor jetting and setting.

Info

Your authorized KTM workshop can recommend the right carburetor tuning.

Two black gear-like mechanical components with evenly spaced teeth, shown against a white background (no text or symbols)

- Clean the chain.

Chain cleaner ( p. 145)

- Mount the steel sprocket.

- Grease the chain.

Universal oil spray ( p. 146)

- Clean the radiator fins.

- Straighten the bent radiator fins carefully.

Condition

Regular use in sand

- Change the piston every 10 operating hours.

8.5 Preparing the vehicle for riding on wet sand

Close-up of a metallic circular object with embossed markings and a central spiral center (no readable text or symbols)

- Check the radiator cap.

Value on the radiator cap 1,8 bar (26 psi)

» If the indicated value does not correspond to the setpoint value:

Warning

Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.

• Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
• Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
• In the event of scalding, rinse the area affected immediately with lukewarm water.

- Change the radiator cap.

8 PREPARING FOR USE

TwinAir RAINCOAT M01106-01

- Mount the air filter rain cover.

Air filter rain cover (79006921000)

Info

Observe the KTM PowerParts fitting instructions.

- Adjust the carburetor jetting and setting.

Info

Your authorized KTM workshop can recommend the right carburetor tuning.

Two black gear-like mechanical components with evenly spaced teeth, displayed against a white background (no text or symbols visible)

- Clean the chain.

Chain cleaner (p. 145)

- Mount the steel sprocket.

- Grease the chain.

Universal oil spray ( p. 146)

- Clean the radiator fins.

- Straighten the bent radiator fins carefully.

Condition

Regular use in sand

- Change the piston every 10 operating hours.

8.6 Preparing the vehicle for riding on wet and muddy circuits

TwinAir RAINCOAT M01106-01

- Mount the air filter rain cover.

Air filter rain cover (79006921000)

Info

Observe the KTM PowerParts fitting instructions.

- Adjust the carburetor jetting and setting.

Info

Your authorized KTM workshop can recommend the right carburetor tuning.

Two black gear-like mechanical components with evenly spaced teeth, shown against a white background (no text or symbols)

• Mount the steel sprocket.
• Clean the motorcycle. (p. 128)
• Straighten the bent radiator fins carefully.

8.7 Preparing vehicle for high temperatures or slow riding

Close-up of a metallic circular object with embossed markings and a central spiral pattern (no readable text or symbols)

- Check the radiator cap.

Value on the radiator cap 1.8 bar (26 psi)

» If the indicated value does not correspond to the setpoint value:

Warning

Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.

• Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
• Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
• In the event of scalding, rinse the area affected immediately with lukewarm water.

- Change the radiator cap.

Two black gear-like mechanical components with evenly spaced teeth, shown against a white background (no text or symbols)

- Adjust the secondary drive to the road conditions.

Info

The transmission oil heats up quickly when the clutch is operated frequently due to an excessively high secondary drive.

- Clean the chain.

Chain cleaner ( p. 145)

• Clean the radiator fins.
• Straighten bent radiator fins carefully.
• Check the coolant level. (p. 112)

8.8 Preparing the vehicle for low temperatures or snow

White rubber cap with 'TwinAir RANCOAT' branding, no additional text or symbols visible

- Mount the air filter rain cover.

Air filter rain cover (79006921000)

Info

Observe the KTM PowerParts fitting instructions.

- Adjust the carburetor jetting and setting.

Info

Your authorized KTM workshop can recommend the right carburetor tuning.

9.1 Checks and maintenance measures when preparing for use

Info

Before every trip, check the condition of the vehicle and ensure that it is safe to operate.

The vehicle must be in perfect technical condition when it is being operated.

H02217-01

• Check the gear oil level. (p. 125)
• Check the electrical system.
• Check the front brake fluid level. ( p. 85)
• Check the rear brake fluid level. (p. 91)
• Check the front brake linings. ( p. 87)
• Check the brake linings of the rear brake. (p. 93)
• Check that the brake system is functioning properly.
• Check the coolant level. (p. 112)
• Check the chain for dirt. (p. 73)
• Check the chain, rear sprocket, engine sprocket, and chain guide. (p. 76)
• Check the chain tension. (p. 74)
• Check the tire condition. (p. 100)
• Check tire pressure. (p. 100)
• Check the spoke tension. (p. 101)

Info

The spoke tension must be checked regularly as incorrect spoke tension will strongly impair riding safety.

• Clean the dust boots of the fork legs. (p. 57)
• Bleed the fork legs. (p. 56)
• Check the air filter.
• Check the settings of all controls and ensure that they can be operated smoothly.
• Check all screws, nuts, and hose clamps regularly for tightness.
• Check the fuel level.

9.2 Starting the vehicle

Danger

Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

• Always make sure there is sufficient ventilation when running the engine.
• Use effective exhaust extraction when starting or running the engine in an enclosed space.

Note

Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.

- Always run the engine warm at a low speed.

Info

If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel evaporate after a long time of standing.

If the float chamber is filled with fresh fuel, the engine starts immediately.

Condition

The motorcycle was stationary for more than 1 week.

- Empty the carburetor float chamber. (p. 124)

- Turn tap handle of the fuel tap to the ON position.

√ Fuel can flow from the fuel tank to the carburetor.

- Remove the motorcycle from the stand.

- Shift the transmission to neutral position.

Condition

The engine is cold.

– Pull the choke lever out as far as possible.

- Press the start button.

Info

Do not open the throttle.

9.3 Starting off

Info

Switch on the light before riding the vehicle. You will be seen earlier by other motorists. When you are riding, the side stand must be folded up and secured with the rubber strap.

- Pull the clutch lever, shift into first gear, release the clutch lever slowly and at the same time open the throttle carefully.

9.4 Shifting, riding

Warning

Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine races.

- Do not change into a low gear at high engine speed.

Info

If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized KTM workshop.

First-gear is used for starting off and for steep inclines.

• Shift into a higher gear when conditions allow (incline, road situation, etc.). To do so, release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever and open the throttle.
• If the choke function was activated, deactivate the choke function after the engine has warmed up.
• After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is 34 open. This will barely reduce the speed, but fuel consumption will be considerably lower.

9 RIDING INSTRUCTIONS

• Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel consumption.
• To shift down, apply the brakes and close the throttle at the same time.
• Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and either open the throttle or shift again.
• Switch off the engine if running at idle speed or stationary for a long time.
  Guideline
  ≥ 2 min
• Avoid frequent and longer slipping of the clutch. This causes the gear oil, engine and cooling system to heat up.
• Ride at a low engine speed instead of at a high engine speed with a slipping clutch.

9.5 Braking

Warning

Danger of accidents Excessively forceful application of the brakes blocks the wheels.

- Adjust application of the brakes to the respective riding situation and riding surface conditions.

Warning

Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency.

- Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)

Warning

Danger of accidents Moisture and dirt impair the brake system.

- Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs.

• 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.

9.6 Stopping, parking

Warning

Risk of misappropriation People who act without authorization endanger themselves and others.

• Do not leave the vehicle unattended if the engine is running.
• Protect the vehicle against access by unauthorized persons.

Warning

Danger of burns Some vehicle components become very hot when the vehicle is operated.

• Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have cooled down.
• Let the vehicle parts cool down before you perform any work on the vehicle.

Note

Material damage The vehicle may be damaged by incorrect procedure when parking.

Significant damage may be caused if the vehicle rolls away or falls over.

The components for parking the vehicle are designed only for the weight of the vehicle.

• Park the vehicle on a firm and level surface.
• Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.

Note

Fire hazard Hot vehicle components pose a fire hazard and explosion risk.

• Do not park the vehicle near to materials which are highly flammable or explosive.

• Allow the vehicle to cool down before covering it.

• Apply the brakes on the motorcycle.

• Shift the transmission to neutral position.
• Press and hold the switch-off button while the engine is idling until the engine stops.
• Turn tap handle of the fuel tap to the OFF position.
• Park the motorcycle on firm ground.

9.7 Transporting

Note

Danger of damage The parked vehicle can roll away or fall over.

- Park the vehicle on a firm and level surface.

Note

Fire hazard Hot vehicle components pose a fire hazard and explosion risk.

• Do not park the vehicle near to materials which are highly flammable or explosive.
• Allow the vehicle to cool down before covering it.

Line drawing of a motorcycle with visible exhaust plume and base mount (no text or symbols)

• Switch off the engine.
• Use tension belts or other suitable devices to secure the motorcycle against falling over or rolling away.

9.8 Refueling

Danger

Fire hazard Fuel is highly flammable.

The fuel in the fuel tank expands when warm and can escape if overfilled.

• Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
• Switch off the engine for refueling.
• Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
• If any fuel is spilled, wipe it off immediately.
• Observe the specifications for refueling.

9 RIDING INSTRUCTIONS

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

• Avoid skin, eye and clothing contact with fuel.
• Immediately consult a doctor if you swallow fuel.
• Do not inhale fuel vapors.
• In case of skin contact, rinse the affected area with plenty of water.
• Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
• Change your clothing in case of fuel spills on them.

Note

Environmental hazard Improper handling of fuel is a danger to the environment.

- Do not allow fuel to enter the groundwater, the soil, or the sewage system.

A 400382-10

• Switch off the engine.
• Open the fuel tank filler cap. (p. 17)
• Fill the fuel tank with fuel up to measurement. It Guideline

Measurement of A		35 mm (1.38 in)
Total fuel tank capacity, approx.	7.5 l(1.98 US gal)		Super unleaded,type C (ROZ95/RON 95/PON91 mixed with2-stroke engine oil,1:60) ( p. 144)
Engine oil, 2-stroke ( p. 143)

- Close the fuel tank filler cap. (p. 18)

10.1 Additional information

Any further work that results from the compulsory work or from the recommended work must be ordered separately and invoiced separately.

Different service intervals may apply in your country, depending on the local operating conditions.

Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.

10.2 Required work

○ One-time interval
- Periodic interval

Every 10 operating hours when used for motorsports
Every 40 operating hours
Every 20 operating hours
After 5 operating hours
After 1 operating hour
Check that the electrical system is functioning properly. ○ ● ● ●
Check and charge the 12-V batteries. ● ● ●
Check the front brake linings. ( p. 87) ● ● ●
Check the brake linings of the rear brake. ( p. 93) ● ● ●
Check the brake discs. ( p. 84) ● ● ●
Check the brake lines for damage and leakage. ● ● ●
Check the rear brake fluid level. ( p. 91) ● ● ●
Check the free travel of the foot brake lever. ( p. 90)			● ● ●
Check the frame. ( p. 79)		● ● ●
Check the link fork. ( p. 79)		● ● ●
Check the fork bearing for play		● ●
Check the heim joint for play		● ●
Check the tire condition. ( p. 100)	○	● ● ●
Check tire pressure. ( p. 100)	○ ● ● ●
Check the wheel bearing for play		● ● ●
Check the wheel hubs		● ● ●
Check the rim run-out.	○ ● ●
Check the spoke tension. ( p. 101)	○	● ● ●
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 76)		● ● ●
Check the chain tension. ( p. 74)	○ ● ● ●
Grease all moving parts (e.g. side stand, hand lever, chain, etc.) and check for smooth operation.		● ● ●
Check/correct the fluid level of the hydraulic clutch. ( p. 81)		● ● ●
Check the front brake fluid level. ( p. 85)		● ● ●
Check the free travel of the hand brake lever. ( p. 84)		● ● ●
Check steering head bearing play. ( p. 62)	○	● ●
Change the spark plug and spark plug connector.			●
Check the reed valve housing, reed valve and intake flange.			● ●
Change the gear oil. ( p. 125)	○ ●
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and incorrect routing.	○ ● ●
Check the antifreeze and coolant level. ( p. 111)	○	● ● ●
Check the cables for damage and for routing without kicks. • • •
Check that the throttle cables are undamaged, routed without sharp bends, and set oor• • •rectly.
Clean the air filter and air filter box. ( p. 69) • • •
Change the glass fiber yarn filling in the main silen-er. ( p. 70) • •
Service the fork.
Perform the shock absorber service. •
Check the tightness of the easily accessible, safety-relevant screws and nuts. ○ • •
Check the headlight setting. ( p. 108) ○ • •
Check the idle speed. • •
Final check: Check the vehicle for operating safety and take a test ride.
Make a service entry in KTM Dealer.net.

10.3 Recommended work

Every 40 operating hours when used for motorsports
Every 10 operating hours when used for motorsports
Every 80 operating hours
Every 40 operating hours
After 20 operating hours
After 10 operating hours
every 12 months
Change the front brake fluid	●
Change the rear brake fluid	●
Change the hydraulic clutch fluid (p. 82)	●
Lubricate the steering head bearing (p. 64)	●
Service the fork	○
Perform the shock absorber service		○
Check the electric starter drive			●	●
Change the piston and check the cylinder.			●	●
Check/adjust the carburetor components.	●		●
Change the needle jet	●	●	●
Perform minor engine service. (Check the exhaust control for functioning and smooth operation. Check the clutch)		●	●	●
Perform major engine service including removing and installing engine. (Change the connecting rod, conrod bearing, and crank pin. Check the transmission and shift mechanism. Change all engine bearings.)			●

○ One-time interval
- Periodic interval

11.1 Checking the basic chassis setting with rider's weight

Info

When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.

Two line drawings of a person riding a motorcycle, showing different positions (no text or symbols)

• For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, link fork and frame, the basic settings of the suspension components must match the rider's weight.
• As delivered, KTM offroad motorcycles are adjusted for an average rider's weight (with full protective clothing). Guideline

Standard rider weight 75 ...

85 kg (165 ... 187 lb.)

• If the rider's weight is above or below this range, the basic setting of the suspension components must be adjusted accordingly.
• Small weight differences can be compensated by adjusting the spring preload, but in the case of large weight differences, the springs must be replaced.

11.2 Compression damping of the shock absorber

The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.

High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.

The high-speed compression adjuster has an effect, for example, when landing after a jump: the rear wheel suspension compresses quickly.

The low-speed compression adjuster has an effect, for example, when riding over long ground swells: the rear wheel suspension compresses slowly.

These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, modifications in the high-speed range affect the compression damping in the low-speed range and vice versa.

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

Caution

Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.

The shock absorber is filled with highly compressed nitrogen.

- Please follow the description provided. (Your authorized KTM workshop will be glad to help.)

Info

The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock absorber.

11 TUNING THE CHASSIS

Technical diagram showing mechanical assembly with numbered components and a close-up view of the component labeled S03468-10

- Turn adjusting screw① clockwise with a screwdriver as far as the last perceptible click.

Info

Do not loosen fitting ^2 !

- Turn counterclockwise by the number of clicks corresponding to the shock absorber type.

Guideline

Low-speed compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks

Info

Turn clockwise to increase the damping; turn counterclockwise to reduce the damping.

11.4 Adjusting the high-speed compression damping of the shock absorber

Caution

Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen.

- Please follow the description provided. (Your authorized KTM workshop will be glad to help.)

Info

The effect of the high-speed compression adjuster can be seen in fast compression of the shock absorber.

Close-up of a car engine component with numbered parts, no visible text or symbols

- Using an open end wrench, turn adjusting screw clockwise all the way.

Info

Do not loosen fitting ^2 !

- Turn counterclockwise by the number of turns corresponding to the shock absorber type.

Guideline

High-speed compression damping
Comfort 2.5 turns
Standard 2 turns
Sport 1 turn

Info

Turn clockwise to increase the damping; turn counterclockwise to reduce the damping.

11.5 Adjusting the rebound damping of the shock absorber

Caution

Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen.

- Please follow the description provided. (Your authorized KTM workshop will be glad to help.)

Close-up of mechanical components including a spring and chain, with no visible text or symbols

• Turn adjusting screw 1 clockwise up to the last perceptible click.
• Turn counterclockwise by the number of clicks corresponding to the shock absorber type.

Guideline

Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks

Info

Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds.

11.6 Measuring the dimension of the rear wheel unloaded

SAG A 402415-10

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 56)

Main work

- Position the sag gage in the rear axle and measure the distance to marking SAG on the rear fender.

Sag gauge (00029090100)

Sag gage pin (00029990010)

- Note the value as dimension A.

Finishing work

- Remove the motorcycle from the lift stand. (p. 56)

11 TUNING THE CHASSIS

11.7 Checking the static sag of the shock absorber

A B 402416-10

• Measure dimension A of rear wheel unloaded. ( p. 49)
• Hold the motorcycle upright with aid of an assistant.
• Measure the distance again between the rear axle and marking SAG on the rear fender using the sag gage.
• Note the value as dimension B.

Info

The static sag is the difference between measurements A and B.

- Check the static sag.

Static sag 37 mm (1.46 in)

» If the static sag is less or more than the specified value: - Adjust the spring preload of the shock absorber. ( p. 51)

11.8 Checking the riding sag of the shock absorber

A C 402417-10

• Measure dimension A of rear wheel unloaded. ( p. 49)
• With another person holding the motorcycle, the rider, wearing full protective clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.

√ The rear wheel suspension levels out.

—Another person again measures the distance between the rear axle and marking SAG on the rear fender using the sag gage.
- Note the value as dimension.

Info

The riding sag is the difference between measurements A and C.

- Check riding sag.

Riding sag 110 mm (4.33 in)

» If the riding sag differs from the specified measurement: -Adjust the riding sag. (p. 52)

11.9 Adjusting the spring preload of the shock absorber

Caution

Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.

The shock absorber is filled with highly compressed nitrogen.

- Please follow the description provided. (Your authorized KTM workshop will be glad to help.)

Info

Before changing the spring preload, make a note of the present setting, e.g., by measuring the spring length.

② ① ④ 402659-10

Preparatory work

• Raise the motorcycle with a lift stand. (p. 56)
• Remove the shock absorber.(p. 65)
• After removing the shock absorber, clean it thoroughly.

Main work

• Loosen screw①.
• Turn adjusting ring② until the spring is no longer under tension.

Hook wrench (90129051000)

Info

If the spring cannot be fully released, the spring must be removed to accurately measure the spring length.

• Measure the total spring length while the spring is not under tension.
• Tension the spring by turning adjusting r② to specified dimension A.

Guideline

Spring preload 10 mm (0.39 in)

Info

Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload.

- Tighten screw①.

Guideline

Screw, shockabsorber adjustingring

M5 5 Nm (3.7

lbf ft)

Finishing work

• Install the shock absorber.(p. 65)
• Remove the motorcycle from the lift stand. (p. 56)

11 TUNING THE CHASSIS

11.10 Adjusting the riding sag

Preparatory work

• Raise the motorcycle with a lift stand. ( p. 56)
• Remove the shock absorber.(p. 65)
• After removing the shock absorber, clean it thoroughly.

Pure diagram of a coiled spring without any text, numbers, or symbols

Main work

- Choose and mount a suitable spring. Guideline

Spring rate
Weight of rider: 65 ...75 kg (143 ... 165 lb.)	57 ... 63 N/mm (325 ...360 lb/in)
Weight of rider: 75 ...85 kg (165 ... 187 lb.)	60 ... 66 N/mm (343 ...377 lb/in)
Weight of rider: 85 ...95 kg (187 ... 209 lb.)	63 ... 69 N/mm (360 ...394 lb/in)

Info

The spring rate is shown on the outside of the spring.

Finishing work

• Install the shock absorber.(p. 65)
• Remove the motorcycle from the lift stand. ( p. 56)
• Check the static sag of the shock absorber. (p. 50)
• Check the riding sag of the shock absorber. ( p. 50)
• Adjust the rebound damping of the shock absorber. ( p. 49)

11.11 Checking the basic setting of the fork

Info

For various reasons, no exact riding sag can be determined for the fork.

Pure line drawing of a stylized bicycle with a circular emblem, no text or symbols present

• As with the shock absorber, smaller differences in the rider's weight can be compensated by the spring preload.
• However, if the fork frequently bottoms out (hard end stop on compression), harder springs must be fitted to avoid damage to the fork and frame.
• If the fork feels unusually hard after extended periods of operation, the fork legs need to be bled.

11.12 Adjusting the compression damping of the fork

Info

The hydraulic compression damping determines the fork suspension behavior.

Close-up of a mechanical component with a numbered callout (1) and S03470-10 label, no readable text or symbols beyond the number.

- Turn white adjuster① clockwise as far as it will go.

Info

Adjuster 1 is located at the upper end of the left fork leg.

The compression damping is located in left fork leg COMP (white adjuster). The rebound damping is located in right fork leg REB (red adjuster).

- Turn counterclockwise by the number of clicks corresponding to the fork type.

Guideline

Compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damping during compression.

11.13 Adjusting the rebound damping of the fork

Info

The hydraulic rebound damping determines the fork suspension behavior.

Close-up of a mechanical component with a numbered annotation (1) and identifier S03472-10, no readable text or symbols beyond the label.

- Turn red adjuster① clockwise as far as it will go.

Info

Adjuster 1 is located at the upper end of the right fork leg.

The rebound damping is located in right fork leg REB (red adjuster). The compression damping is located in left fork leg COMP (white adjuster).

- Turn counterclockwise by the number of clicks corresponding to the fork type.

Guideline

Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks

11 TUNING THE CHASSIS

Info

Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds.

11.14 Handlebar position

A B M00993-10

On the upper triple clamp, there are 2 holes at a distant A to each other.

Hole distance A 15 mm (0.59 in)

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

Hole distance B 3.5 mm (0.138 in)

The handlebar can be mounted in four different positions. This allows the handlebar to be mounted in the most comfortable position for the rider.

11.15 Adjusting the handlebar position

Warning

Danger of accidents A repaired handlebar poses a safety risk.

If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result.

- Change the handlebar if the handlebar is damaged or bent.

Technical diagram showing assembly steps of a mechanical component with numbered parts and a labeled part M00993-11

- Remove screws①. Take off the handlebar clamps. Remove the handlebar and lay it to one side.

Info

Cover the components to protect them against damage. Do not kink the cables and lines.

• Remove screws②. Take off the handlebar supports.
• Place the handlebar supports in the required position. Mount and tighten screws②.

Guideline

Screw, handle-bar support

M10 40 Nm (29.5 lbf ft)Loctite®243TM

Info

Position the left and right handlebar supports evenly.

- Position the handlebar.

Info

Make sure the cables and wiring are positioned correctly.

- Position the handlebar clamps. Mount screw and tighten evenly.

Guideline

Screw, handlebar clamp

M8 20 Nm (14.8 lbf ft)

Info

Make sure the gap widths are even.

12 SERVICE WORK ON THE CHASSIS

12.1 Raising the motorcycle with a lift stand

Line drawing of a motorcycle with front wheel and side wheel, mounted on a base (no text or symbols)

Note

Danger of damage The parked vehicle can roll away or fall over.

- Park the vehicle on a firm and level surface.

- Raise the motorcycle at the frame underneath the engine.

Lift stand (78129955100)

√ Neither wheel is in contact with the ground.

- Secure the motorcycle against falling over.

12.2 Removing the motorcycle from the lift stand

Note

Danger of damage The parked vehicle can roll away or fall over.

- Park the vehicle on a firm and level surface.

Line drawing of a motorcycle with labeled parts (no text or symbols on the diagram itself)

- Remove the motorcycle from the lift stand.

- Remove the lift stand.

- To park the motorcycle, press side sta ^1 to the ground with your foot and lean the motorcycle on it.

Info

When you are riding, the side stand must be folded up and secured with the rubber strap.

12.3 Bleeding the fork legs

① ① S03463-10

Preparatory work

- Raise the motorcycle with a lift stand. (p. 56)

Main work

- Release bleeder screws①.

√ Any excess pressure escapes from the interior of the fork.

- Tighten the bleeder screws.

Finishing work

- Remove the motorcycle from the lift stand. (p. 56)

12.4 Cleaning the dust boots of the fork legs

Preparatory work

• Raise the motorcycle with a lift stand. (p. 56)
• Remove the fork protector. (p. 57)

Main work

- Push dust boots of both fork legs downward.

Close-up of a bicycle tire tread assembly with labeled parts (no text or symbols on the tire itself)

Info

The dust boots remove dust and coarse dirt particles from the inside fork tubes. Over time, dirt can accumulate behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak.

Warning

Danger of accidents Oil or grease on the brake discs reduces the braking effect.

• Always keep the brake discs free of oil and grease.
• Clean the brake discs with brake cleaner when necessary.

- Clean and oil the dust boots and inner fork tubes of both fork legs.

Universal oil spray ( p. 146)

• Press the dust boots back into their installation position.
• Remove excess oil.

Finishing work

• Install the fork protector. (p. 58)
• Remove the motorcycle from the lift stand. (p. 56)

12.5 Removing the fork protector

Diagram showing bicycle wheel assembly with numbered components and a label V00332-10 at bottom right.

• Remove screws① and take off the clamp.
• Remove screws② and take off the left fork protector.
• Remove screws ③ and take off the right fork protector.

12 SERVICE WORK ON THE CHASSIS

12.6 Installing the fork protector

② ① ③ V00332-11

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

Guideline

Remaining screws, chassis

M6 10 Nm (7)

4 lbf ft)

- Position the brake line, wiring harness, and clamp. Mount and tighten screws ②.

- Position the fork protector on the right fork leg. Mount and tighten screws ③.

Guideline

Remaining screws, chassis

M6 10 Nm (7

4 lbf ft)

12.7 Removing the fork legs

Preparatory work

• Raise the motorcycle with a lift stand. (p. 56)
• Remove the front wheel. (p. 96)
• Remove the headlight mask with the headlight. (p. 106)

① ② ② E00375-10

Main work

• Remove screws 1 and take off the clamp.
• Remove the cable tie.
• Remove screws ② and take off the brake caliper.
• Hang the brake caliper and the brake line loosely to the side.

③ ④ ③ ④ S03475-10

• Loosen screws③. Remove the left fork leg.
• Loosen screws 4. Remove the right fork leg.

12.8 Installing the fork legs

① ① S03463-10

Main work

- Position the fork legs.

√ Bleeder screws ① are positioned toward the front.

Info

The rebound damping is located in right fork leg REB (red adjuster). The compression damping is located in left fork leg COMP (white adjuster).

Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from the top) must be flush with the upper edge of the upper triple clamp.

Close-up mechanical assembly showing three numbered components (②, ③) with no visible text or symbols

- Tighten screws②.

Guideline

Screw, top triple clamp

M8 20 Nm (14.8 lbf ft)

- Tighten screws ③.

Guideline

Screw, bottom triple clamp

M8 15 Nm (11.1 lbf ft)

Technical diagram showing mechanical assembly with numbered components, likely for assembly or maintenance instructions

- Position the brake caliper, and mount and tighten scr4s Guideline

Screw, frontbrake caliper

M8 25 Nm (18.4 lbf ft)Loctite®243TM

- Mount the cable ties.

- Position the brake line, the wiring harness, and the clamp. Mount and tighten screw⑤.

Finishing work

• Install the front wheel.(p. 97)
• Install the headlight mask with the headlight. ( p. 106)
• Check the headlight setting. ( p. 108)

12.9 Removing the lower triple clamp

Preparatory work

• Raise the motorcycle with a lift stand. (p. 56)
• Remove the front wheel. (p. 96)
• Remove the headlight mask with the headlight. ( p. 106)
• Remove the fork legs.(p. 58)
• Remove front fender. (p. 64)
• Remove the handlebar cushion.

12 SERVICE WORK ON THE CHASSIS

Close-up of mechanical wiring and components with no visible text or symbols

Close-up of a motorcycle's front wheel assembly with numbered components (no visible text or symbols)

④ ⑤ S03651-10

Main work

- Remove screws 1 and hang the combination instrument holder to the side.

• Remove screw ②.
• Loosen screw③. Take off the upper triple clamp with the handlebar and hang them to the side.

Info

Cover the components to protect them against damage. Do not kink the cables and lines.

• Remove O-ring 4. Remove protective ring 5.
• Take off the lower triple clamp with the steering stem.
• Remove the upper steering head bearing.

12.10 Installing the lower triple clamp

① ② ③ V00359-10

Main work

- Clean the bearing and sealing elements, check for damage, and grease.

High viscosity grease ( p. 145)

• Insert the lower triple clamp with the steering stem. Mount upper steering head bearing.
• Check whether upper steering head se1 is correctly positioned.
• Mount protective ring② and O-ring③.

Close-up of a mechanical assembly with hoses and connectors, no visible text or symbols

• Position the upper triple clamp with the handlebar.
• Position the clutch line and wiring harness.
• Mount screw 4 but do not tighten yet.

Close-up of mechanical components with visible wiring and connectors (no text or symbols)

- Position the combination instrument holder, and mount and tighten screws 5.

Guideline

Remaining screws, chassis

M6 10 Nm (7.4 lbf ft)

6 6 S03463-11

- Position the fork legs.

Bleeder screws 6 are positioned toward the front.

Info

The rebound damping is located in right fork leg REB (red adjuster). The compression damping is located in left fork leg COMP (white adjuster).

Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from the top) must be flush with the upper edge of the upper triple clamp.

Close-up of mechanical components with numbered annotations (7) and identifier S03648-10, no readable text or symbols beyond labels.

- Tighten screws⑦.

Guideline

Screw, bottom triple clamp

M8 15 Nm (1)

1.1 lbf ft)

Close-up of a mechanical assembly with hoses and components, no visible text or symbols

- Tighten screw 4.

Guideline

Screw, top steering head

M20x1.5 12 Nm (8.9 lbf ft)

12 SERVICE WORK ON THE CHASSIS

Close-up of mechanical components with no visible text or symbols

- Tighten screw 8.

Guideline

Screw, top steering stem

M8 20 Nm (14.8 lbf ft)

Close-up of mechanical components with numbered annotations (9) and identifier S03648-11, no readable text or symbols beyond labels.

- Tighten screws ⑨.

Guideline

Screw, top triple clamp

M8 20 Nm (14.8 lbf ft)

11 10 10 E00375-13

- Position the brake caliper, and mount and tighten screws Guideline

Screw, frontbrake caliper

M8 25 Nm (18.4 lbf ft)Loctite®243TM

• Mount the cable ties.
• Position the brake line, the wiring harness, and the clamp. Mount and tighten screw ^11 .

Finishing work

• Mount the handlebar cushion.
• Install front fender. (p. 64)
• Install the front wheel. (p. 97)
• Install the headlight mask with the headlight. ( p. 106)
• Check that the wiring harness, throttle cables, and brake and clutch lines can move freely and are routed correctly.
• Check steering head bearing play. (p. 62)
• Remove the motorcycle from the lift stand. (p. 56)
• Check the headlight setting. (p. 108)

12.11 Checking steering head bearing play

Warning

Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components.

- Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.)

Info

If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.

Diagram of a motorcycle with directional arrows indicating motion or force (no text or symbols)

Preparatory work

- Raise the motorcycle with a lift stand. (p. 56)

Main work

- Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel.

Play should not be detectable on the steering head bearing.

» If there is detectable play:

- Adjust the steering head bearing play (p. 63)

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

It must be possible to move the handlebar easily over the entire steering range. There should be no detectable detent positions.

» If detent positions are detected:

- Adjust the steering head bearing play (p. 63)

- Check the steering head bearing and change if necessary.

Finishing work

- Remove the motorcycle from the lift stand. (p. 56)

12.12 Adjusting the steering head bearing play

① ② ③ ① S03652-10

Preparatory work

- Raise the motorcycle with a lift stand. (p. 56)

Main work

- Loosen screws ① and ②.

- Loosen and retighten screw ^3 .

Guideline

Screw, top steering head

M20x1.5 12 Nm (8.9 lbf ft)

- Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.

- Tighten screws①.

Guideline

Screw, top triple clamp

M8 20 Nm (14.8 lbf ft)

- Tighten screw②.

Guideline

Screw, top steering stem

M8 20 Nm (14.8 lbf ft)

Finishing work

- Check steering head bearing play. (p. 62)

- Remove the motorcycle from the lift stand. ( p. 56)

◀

12 SERVICE WORK ON THE CHASSIS

12.13 Lubricating the steering head bearing

H02387-01

• Remove the lower triple clamp. (p. 59)
• Install the lower triple clamp. (p. 60)

12.14 Removing front fender

Preparatory work

- Remove the headlight mask with the headlight. (p. 106)

Main work

- Remove screws 1.

Close-up of a human torso with two metallic clips and a numbered marker (1) on the chest, no visible text or symbols.

Close-up of a mechanical component with labeled parts (number 2) and no visible text or symbols on the main structure.

- Remove screws ②. Take off front fender.

12.15 Installing front fender

Close-up of a mechanical component with labeled parts (1) and identifier VD0341-11, showing no readable text or symbols beyond the label.

Main work

- Position front fender. Mount and tighten scre①. Guideline

Remaining screws, chassis

M6 10 Nm (7.4 lbf ft)

Close-up of a medical or laboratory setup with two cylindrical components and a numbered label (2) on the central component, no readable text or symbols.

- Mount and tighten screw②.

Guideline

Remaining screws, chassis

M6 10 Nm (7.4 lbf ft)

Finishing work

• Install the headlight mask with the headlight. ( p. 106)
• Check the headlight setting. ( p. 108)

12.16 Removing the shock absorber

① ② ③ S03479-10

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 56)

Main work

• Remove screw ① and lower the rear wheel with the link fork as far as possible without blocking the rear wheel. Secure the rear wheel in this position.
• Remove screw②, push splash protecto③ to the side, and remove the shock absorber.

12.17 Installing the shock absorber

① ② ③ S03479-11

Main work

- Push splash protector ^1 to the side and position the shock absorber. Mount and tighten screw ^2 .

Guideline

Screw, top shock absorber

M12 80 Nm (59 lbf ft)Loctite®2701TM

- Mount and tighten screw③.

Guideline

Screw, bottom shock absorber

M12 80 Nm (59 lbf ft)Loctite®2701TM

Info

The heim joint for the shock absorber on the link fork is Teflon coated. It must not be lubricated with grease, nor with any other lubricants. Lubricants dissolve the Teflon coating, thereby drastically reducing the service life.

Finishing work

- Remove the motorcycle from the lift stand. (p. 56)

12 SERVICE WORK ON THE CHASSIS

12.18 Removing the seat

Close-up of a mechanical component with layered material and a numbered annotation (1), no readable text or symbols present.

- Remove screw ① on the left side.

Simple line drawing of a boat hull with an arrow indicating direction (no text or symbols)

- Raise the rear of the seat, pull the seat back, and lift it off.

12.19 Mounting the seat

Simple line drawing of a boat hull with an arrow indicating direction (no text or symbols)

• Mount the front of the seat on the collar bushings of the fuel tank, lower the seat at the rear, and push the seat forward.
• Make sure the seat is correctly latched in place.

Close-up of a car's wing with a textured surface and a numbered marker (1) pointing to the edge, no visible text or symbols on the main subject.

- Mount and tighten screw① on the left side. Guideline

Remaining screws, chassis

M6 10 Nm (7)

4 lbf ft)

12.20 Removing the air filter box cover

Preparatory work

- Remove the seat. ( p. 66)

Close-up of a white car's side panel with a numbered marker and 'K01348-10' label (no readable text or symbols beyond labels)

Condition

The air filter box cover is secured.

- Remove screw①.

Close-up of a white car's front edge with visible tire marking and labeled point A (no text or symbols beyond labels)

- Pull off the air filter box cover in a laterally and take it off at the front.

12.21 Installing the air filter box cover

A B K01348-12

Main work

- Insert the air filter box cover in a and clip it into area B.

Close-up of a white car's front bumper with a numbered marker and vehicle number K01348-10 (no readable text or symbols beyond markings)

Condition

The air filter box cover is secured.

- Mount and tighten screw①.

Guideline

Screw, air filter box cover

EJOT PT®K60x20-Z

3 Nm (2.2 lbf ft)

Finishing work

- Mount the seat. (p. 66)

12 SERVICE WORK ON THE CHASSIS

12.22 Removing the air filter

Note

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

Dust and dirt will enter the engine without an air filter.

- Never start to use the vehicle without an air filter.

Note

Environmental hazard Hazardous substances cause environmental damage.

- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Preparatory work

• Remove the seat. (p. 66)
• Remove the air filter box cover. ( p. 67)

Main work

• Detach retaining tab①. Remove air filter with air filter support.
• Remove air filter from air filter support.

TwinAir S03482-10

12.23 Installing the air filter

Simple diagram of a rounded square shape with an arrow labeled 'A' pointing to its top-right corner, no text or symbols present.

Main work

• Mount the clean air filter on the air filter support.
• Grease the air filter in area.

Long-life grease (p. 145)

Twin Air S03483-10

• Insert air filter and position retaining ⬤1 in bushing Ⓑ.
  √ The air filter is correctly positioned.
• Insert retaining tab②.
  √ Retaining pin③ is secured with retaining ta②.

Info

If the air filter is not mounted correctly, dust and dirt may enter the engine and result in damage.

Finishing work

• Install the air filter box cover. ( p. 67)
• Mount the seat. (p. 66)

12.24 Cleaning the air filter and air filter box

Note

Environmental hazard Hazardous substances cause environmental damage.

- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info

Do not clean the air filter with fuel or petroleum since these substances attack the foam.

TwinAir WWW.TWINAIR.COM 102191-01

Preparatory work

• Remove the seat. (p. 66)
• Remove the air filter box cover. ( p. 67)
• Remove the air filter. (p. 68)

Main work

- Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.

Air filter cleaner ( p. 145)

Info

Only press the air filter to dry it, never wring it out.

• Oil the dry air filter with a high-grade air filter oil.
  Oil for foam air filter ( p. 145)
• Clean the air filter box.
• Clean the intake flange and check it for damage and tightness.

Finishing work

• Install the air filter.(p. 68)
• Install the air filter box cover. (p. 67)
• Mount the seat. (p. 66)

12.25 Preparing air filter box cover for securing

A S03499-10

Preparatory work

• Remove the seat. ( p. 66)
• Remove the air filter box cover. ( p. 67)

Main work

- Drill a hole at marking A.

Guideline

Diameter 6 mm (0.24 in)

Finishing work

• Install the air filter box cover. ( p. 67)
• Mount the seat. (p. 66)

12 SERVICE WORK ON THE CHASSIS

12.26 Removing the main silencer

Warning

Danger of burns The exhaust system gets very hot when the vehicle is driven.

- Allow the exhaust system to cool down before performing any work on the vehicle.

Technical diagram showing mechanical assembly with labeled parts, including numbered annotations 1 and 2.

• Remove screws 1.
• Pull off the main silencer with rubber sleeve and the spring ring from the manifold.

12.27 Installing the main silencer

Close-up of a camera lens assembly with numbered components (1 and 2), no visible text or symbols beyond labels

• Mount the main silencer with rubber sleep and the spring rings.
• Mount and tighten screws②

Guideline

Remaining screws, chassis

M6 10 Nm (7)

4 lbf ft)

12.28 Changing the glass fiber yarn filling in the main silencer

Warning

Danger of burns The exhaust system gets very hot when the vehicle is driven.

- Allow the exhaust system to cool down before performing any work on the vehicle.

Info

Over time, the fibers of the glass fiber yarn escape and the damper "burns" out.

Not only is the noise level higher, but the performance characteristics change.

Preparatory work

- Remove main silencer. (p. 70)

1 2 3 4 5 V01636-10

Main work

• Remove screws①. Pull out inner tub② with O-ring③.
• Pull glass fiber yarn fillin4 from the inner tube.
• Clean the parts that need to be reinstalled and check for damage.
• Mount new glass fiber yarn filling on the inner tube.
• Push outer tube⑤ over the inner tube with the new glass fiber yarn filling and the O-ring.
• Mount and tighten all screw ^1 .

Guideline

Screws on main silencer

M5 7 Nm (5.2

lbf ft)

Finishing work

- Install the main silencer. (p. 70)

12.29 Removing the fuel tank

Danger

Fire hazard Fuel is highly flammable.

The fuel in the fuel tank expands when warm and can escape if overfilled.

• Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
• Switch off the engine for refueling.
• Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
• If any fuel is spilled, wipe it off immediately.
• Observe the specifications for refueling.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

• Avoid skin, eye and clothing contact with fuel.
• Immediately consult a doctor if you swallow fuel.
• Do not inhale fuel vapors.
• In case of skin contact, rinse the affected area with plenty of water.
• Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
• Change your clothing in case of fuel spills on them.
• Keep fuels correctly in a suitable canister, and out of the reach of children.

Preparatory work

- Remove the seat. (p. 66)

12 SERVICE WORK ON THE CHASSIS

Close-up of a mechanical component with two cylindrical parts and labeled features (no readable text or symbols)

Main work

• Turn tap handle of the fuel tap to the OFF position.
• Pull off the fuel hose.

Info

Remaining fuel may flow out of the fuel hose.

Close-up of a white mechanical component with a circular opening and two screws, labeled with number 2 (no readable text or symbols beyond the label)

• Remove screws ① with the collar bushings.
• Hang the horn and horn bracket to one side.

- Remove screw ② with the rubber bushing.

- Remove the hose from the fuel tank breather.

Close-up of a motorcycle's front wheel and side-mounted sensors, showing mechanical components (no text or symbols visible)

- Pull both spoilers off laterally from the radiator mount and lift off the fuel tank.

12.30 Installing the fuel tank

Danger

Fire hazard Fuel is highly flammable.

The fuel in the fuel tank expands when warm and can escape if overfilled.

• Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
• Switch off the engine for refueling.
• Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
• If any fuel is spilled, wipe it off immediately.
• Observe the specifications for refueling.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

• Avoid skin, eye and clothing contact with fuel.
• Immediately consult a doctor if you swallow fuel.
• Do not inhale fuel vapors.
• In case of skin contact, rinse the affected area with plenty of water.
• Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
• Change your clothing in case of fuel spills on them.

Close-up of a robotic arm joint with visible mechanical components and directional arrows (no text or symbols)

Main work

• Check throttle cable routing. (p. 79)
• Position the fuel tank and fit the two spoilers to the sides in front of the radiator bracket.
• Make sure that no cables or throttle cables are trapped or damaged.

Close-up of a mechanical component with a numbered callout pointing to a central hole (no text or symbols visible)

• Attach the fuel tank breather hose.
• Mount and tighten screw with the rubber bushing. Guideline

Remaining screws, chassis

M6 10 Nm (7)

4 lbf ft)

- Position the horn with the horn bracket.

Close-up of a robotic arm with two numbered components (②) and a V00350-11 label, no readable text or symbols beyond labels.

- Mount and tighten screw② with the collar bushings. Guideline

Remaining screws, chassis

M6 10 Nm (7)

4 lbf ft)

- Connect the fuel hose.

Finishing work

- Mount the seat. (p. 66)

12.31 Checking the chain for dirt

Abstract line drawing of a chain with an eye symbol above it, no text or symbols present

- Check the chain for heavy soiling. » If the chain is very dirty: - Clean the chain. (p. 74)

12 SERVICE WORK ON THE CHASSIS

12.32 Cleaning the chain

Warning

Danger of accidents Lubricants on the tires reduces the road grip.

- Remove lubricants from the tires using a suitable cleaning agent.

Warning

Danger of accidents Oil or grease on the brake discs reduces the braking effect.

- Always keep the brake discs free of oil and grease.

- Clean the brake discs with brake cleaner when necessary.

Note

Environmental hazard Hazardous substances cause environmental damage.

- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info

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

Diagram of a mechanical chain with spray and motion lines, no text or symbols present

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 56)

Main work

- Rinse off loose dirt with a soft jet of water.

- Remove old grease residue with chain cleaner.

Chain cleaner ( p. 145)

- After drying, apply chain spray.

Off-road chain spray ( p. 145)

Finishing work

- Remove the motorcycle from the lift stand. (p. 56)

12.33 Checking the chain tension

Warning

Danger of accidents Incorrect chain tension damages components and results in accidents.

If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded.

If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel locks or the engine will be damaged.

- Check the chain tension regularly.

- Set the chain tension in accordance with the specification.

Preparatory work

- Raise the motorcycle with a lift stand. (p. 56)

A B 1 V00354-10

Main work

- Pull the chain at the end of the chain sliding piece upward to measure chain tension.

Info

Lower chain section① must be taut.

When the chain guard is mounted, it must be possible to pull up the chain at least to the point where it makes contact with chain guard B.

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

Chain tension 55 ... 58 mm

(2.17 ... 2.28 in)

» If the chain tension does not meet the specification: - Adjust the chain tension. ( p. 75)

Finishing work

- Remove the motorcycle from the lift stand. (p. 56)

12.34 Adjusting the chain tension

Warning

Danger of accidents Incorrect chain tension damages components and results in accidents.

If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel locks or the engine will be damaged.

- Check the chain tension regularly. - Set the chain tension in accordance with the specification.

Preparatory work

- Raise the motorcycle with a lift stand. (p. 56) - Check the chain tension. (p. 74)

12 SERVICE WORK ON THE CHASSIS

A 3 4 2 1 3 A 4 2 E00330-10

Main work

• Loosen nut①.
• Loosen nuts②.
• Adjust the chain tension by turning adjusting screws left and right.
  Guideline

Chain tension 55 ... 58 mm (2.17 ... 2.28 in)

Turn adjusting screws3 on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marA. The rear wheel is then correctly aligned.

• Tighten nuts ②.
• Make sure that chain adjuster④ are fitted correctly on adjusting screws③.
• Tighten nut 1.

Guideline

Nut, rear wheel spin-dle

M20x1.5 80 Nm (59 lbf ft)

Info

The wide adjustment range of the chain adjusters (32 mm (1.26 in)) enables different secondary ratios with the same chain length.

Chain adjusters 4 can be turned by 180°.

Finishing work

- Remove the motorcycle from the lift stand. (p. 56)

12.35 Checking the chain, rear sprocket, engine sprocket, and chain guide

Preparatory work

- Raise the motorcycle with a lift stand. (p. 56)

Main work

• Shift the transmission into neutral.
• Check the chain, rear sprocket, and engine sprocket for wear.
  » If the chain, rear sprocket or engine sprocket is worn:
• Change the drivetrain kit.

400227-01

Info

The engine sprocket, rear sprocket, and chain should always be replaced together.

A B 1 2 3 16 17 18 400987-10

- Pull on the top section of the chain with the specified weight A.

Guideline

Weight, chain wear measurement

10 ... 15 kg (22 ... 33 lb.)

- Measure distance B of 18 chain rollers in the lower chain section.

Info

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

Maximum distance B from 18 chain rollers at the longest chain section

272 mm (10.71 in)

» If distance B is greater than the specified measurement:
- Change the drivetrain kit.

Info

When a new chain is mounted, the rear sprocket and engine sprocket should also be changed. New chains wear out faster on old, worn sprockets.

Mechanical assembly diagram showing chain link components and a close-up of a chain attachment (no text or symbols)

- Check the chain sliding guard for wear.

» If the lower edge of the chain pins is in line with, or below, the chain sliding guard:
- Change the chain sliding guard.

- Check that the chain sliding guard is firmly seated.

» If the chain sliding guard is loose:

- Tighten screws on the chain sliding guard. Guideline

Screw, chain sliding guard

M6 6 Nm (4.4 lbf ft)Loctite®243TM

12 SERVICE WORK ON THE CHASSIS

Mechanical assembly diagram showing chain link and gear mechanism (no text or symbols)

Two identical electronic device icons with checkmark and cross symbols, no readable text or labels

Close-up of a mechanical gear assembly with chain links and mounting holes (no visible text or symbols)

- Check chain sliding piece for wear.

» If the lower edge of the chain pins is in line with or below the chain sliding piece:

- Change the chain sliding piece.

- Check that the chain sliding piece is firmly seated.

» If the chain sliding piece is loose:

- Tighten screw on the chain sliding piece. Guideline

Screw, chain sliding piece

M8 15 Nm

(11.1 lbf ft)

- Check the chain guide for wear.

Info

Wear can be seen on the front of the chain guide.

» If the light part of the chain guide is worn:

- Change the chain guide.

- Check that the chain guide is firmly seated.

» If the chain guide is loose:

- Tighten the screws on the chain guide. Guideline

Remaining screws, chassis

M6 10 Nm

(7.4 lbf ft)

Finishing work

- Remove the motorcycle from the lift stand. (p. 56)

12.36 Checking the frame

Mechanical component with circular and rectangular features, no visible text or symbols

- Check the frame for cracks and deformation.

» If the frame exhibits cracks or deformation due to a mechanical impact:

- Change the frame.

Info

Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by KTM.

12.37 Checking the link fork

Mechanical bracket component (no text or symbols visible)

- Check the link fork for damage, cracking, and deformation.

» If the link fork shows signs of damage, cracking, or deformation:

- Change the link fork.

Info

Always replace a damaged link fork. Repairing the link fork is not authorized by KTM.

12.38 Checking throttle cable routing

Warning

Danger of accidents The throttle cable may slip out of the guide if routed incorrectly.

The throttle slide will then no longer be closed and the speed can no longer be controlled.

- Make sure that the throttle cable routing and the play in the throttle cable comply with the specification.

Preparatory work

- Remove the seat. (p. 66)

- Remove the fuel tank (p. 71)

12 SERVICE WORK ON THE CHASSIS

Close-up of a motorcycle's engine and wheel assembly with visible hoses and sensors (no text or symbols)

Main work

- Check throttle cable routing.

The throttle cable must be routed behind the handlebar, on the right of the frame, and to the carburetor. The throttle cable must be secured behind the fuel tank contact area rubber strap.

» If the throttle cable routing is not as specified: - Correct throttle cable routing.

Finishing work

• Install the fuel tank. (p. 72)
• Mount the seat. (p. 66)

12.39 Checking the rubber grip

3D rendered image of a mechanical component with an eye symbol and no visible text or labels

- Check the rubber grips on the handlebar for damage, wear, and looseness.

Info

The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the right. The left sleeve is clamped onto the handlebar. The rubber grip can only be replaced with the sleeve or the throttle tube.

» If a rubber grip is damaged or worn: - Change the rubber grip.

- Check that screw① is firmly seated. Guideline

5Nm ① A K00547-10

Screw, fixed grip

M4 5 Nm (3.7

lbf ft)

Loctite®243TM

Diamond A must be positioned visibly as shown in the figure.

12.40 Adjusting the basic position of the clutch lever

Close-up of a mechanical component with labeled parts, no readable text or symbols present

- Adjust the basic position of the clutch lever to your hand size by turning adjusting screw①.

Info

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

Turn the adjusting screw clockwise to increase 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.

12.41 Checking/correcting the fluid level of the hydraulic clutch

Warning

Skin irritation Brake fluid causes skin irritation.

• Keep brake fluid out of the reach of children.
• Wear suitable protective clothing and safety glasses.
• Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
• Consult a doctor immediately if brake fluid has been swallowed.
• Rinse the affected area with plenty of water in the event of contact with the skin.
• Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
• If brake fluid spills on to your clothing, change the clothing.

Note

Environmental hazard Hazardous substances cause environmental damage.

- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info

The fluid level rises with increasing wear of the clutch facing discs.

Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.

Only use clean brake fluid from a sealed container.

① ② ③ E00337-10

• Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
• Remove screws①.
• Remove cover ② with membrane ③.
• Check the fluid level.

Fluid level below container rim

4 mm (0.16 in)

» If the level of the fluid does not meet specifications:

12 SERVICE WORK ON THE CHASSIS

- Correct the fluid level of the hydraulic clutch.

Brake fluid DOT 4 / DOT 5.1 (p. 143)

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

Info

Clean up overflowed or spilled brake fluid immediately with water.

12.42 Changing the hydraulic clutch fluid

Warning

Skin irritation Brake fluid causes skin irritation.

• Keep brake fluid out of the reach of children.
• Wear suitable protective clothing and safety glasses.
• Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
• Consult a doctor immediately if brake fluid has been swallowed.
• Rinse the affected area with plenty of water in the event of contact with the skin.
• Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
• If brake fluid spills on to your clothing, change the clothing.

Note

Environmental hazard Hazardous substances cause environmental damage.

- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info

Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.

Only use clean brake fluid from a sealed container.

① ② ③ E00337-10

• Move the hydraulic clutch fluid reservoir mounted on the handlebar into a horizontal position.
• Remove screws 1.
• Take off cover② with membrane③.

④ ⑤ E00843-10

Close-up of a mechanical component with numbered callouts (6 and ⑥), no readable text or symbols beyond the number and label.

- Fill bleeding syringe④ with the appropriate hydraulic fluid.

Syringe (50329050000)

Brake fluid DOT 4 / DOT 5.1 ( p. 143)

- On the clutch slave cylinder, remove the bleeder protection cap, release bleeder screw and mount bleeding syringe 4.

• Now press the fluid into the system until it emerges from hole ⑥ of the master cylinder without bubbles.
• Occasionally extract the fluid from the master cylinder reservoir to prevent overflowing.
• Remove the bleeding syringe. Tighten the bleeder screw. Mount the protection cap.
• Correct the fluid level of the hydraulic clutch. Guideline

Fluid level below container rim

4 mm (0.16 in)

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

Info

Immediately clean up any brake fluid that has overflowed or spilled using water.

[NO TEXT]

13.1 Checking the free travel of the hand brake lever

Warning

Danger of accidents The brake system fails in the event of overheating.

If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit.

- Set the free travel on the hand brake lever in accordance with the specification.

• Push the hand brake lever to the handlebar and check free travel Ⓐ.
  Free travel of hand brake ≥ 3 mm (≥ 0.12 in) lever
  » If the free travel does not match the specification:
• Adjust the free travel of the handbrake lever. ( p. 84)

S03617-10

13.2 Adjusting the free travel of the handbrake lever

• Check the free travel of the hand brake lever. (p. 84)
• Adjust the free travel of the handbrake lever with adjustment screw ①.

Info

S03610-11

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

Turn the adjusting 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.

13.3 Checking the brake discs

Warning

Danger of accidents Worn-out brake discs reduce the braking effect.

- Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.)

400257-10

- Check the front and rear brake disc thickness at multiple points for the dimension.

Info

Wear reduces the thickness of the brake disc around the contact surface of the brake linings.

Brake discs - wear limit
front 2.5 mm (0.098 in)
rear 3.5 mm (0.138 in)

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

• Change the front brake disc.
• Change the rear brake disc

- Check the front and rear brake discs for damage, cracking, and deformation.

» If the brake disc exhibits damage, cracking, or deformation:

• Change the front brake disc
• Change the rear brake disc

13.4 Checking the front brake fluid level

Warning

Danger of accidents An insufficient brake fluid level will cause the brake system to fail.

If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.

- Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)

Warning

Danger of accidents Old brake fluid reduces the braking effect.

- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)

① A S03618-10

• Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
• Check the brake fluid level in level vie①.

» If an air bubble is visible in upper range of the level viewer A:

- Add the front brake fluid (p. 86)

13.5 Adding front brake fluid

Warning

Danger of accidents An insufficient brake fluid level will cause the brake system to fail.

If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.

- Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)

Warning

Skin irritation Brake fluid causes skin irritation.

• Keep brake fluid out of the reach of children.
• Wear suitable protective clothing and safety glasses.
• Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
• Consult a doctor immediately if brake fluid has been swallowed.
• Rinse the affected area with plenty of water in the event of contact with the skin.
• Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
• If brake fluid spills on to your clothing, change the clothing.

Warning

Danger of accidents Old brake fluid reduces the braking effect.

- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)

Note

Environmental hazard Hazardous substances cause environmental damage.

- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info

Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.

Only use clean brake fluid from a sealed container.

Preparatory work

- Check the front brake linings. (p. 87)

Technical diagram showing mechanical assembly steps with numbered components and a close-up of a mechanical part labeled S03619-10.

Main work

• Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
• Remove screws①.
• Take off cover② with membrane③.
• Add brake fluid to level A.

Guideline

Level A (brake fluid level below reservoir rim)

5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 (p. 143)

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

Info

Immediately clean up any brake fluid that has overflowed or spilled using water.

13.6 Checking the front brake linings

Warning

Danger of accidents Worn-out brake linings reduce the braking effect.

- Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.)

Technical diagram of a mechanical assembly with labeled component A and reference number E00342-10 (no readable text or symbols beyond labels)

- Check the brake linings for minimum thickness.

Minimum thickness A

≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

- Change the brake linings of the front brake. (p. 87)

- Check the brake linings for damage and cracking.

» If damage or wear is encountered:

- Change the brake linings of the front brake. (p. 87)

13.7 Changing the brake linings of the front brake

Warning

Danger of accidents Incorrect servicing will cause the brake system to fail.

- Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.)

Warning

Skin irritation Brake fluid causes skin irritation.

• Keep brake fluid out of the reach of children.
• Wear suitable protective clothing and safety glasses.
• Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
• Consult a doctor immediately if brake fluid has been swallowed.
• Rinse the affected area with plenty of water in the event of contact with the skin.
• Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
• If brake fluid spills on to your clothing, change the clothing.

Warning

Danger of accidents Old brake fluid reduces the braking effect.

- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)

Warning

Danger of accidents Oil or grease on the brake discs reduces the braking effect.

• Always keep the brake discs free of oil and grease.
• Clean the brake discs with brake cleaner when necessary.

Warning

Danger of accidents Brake linings which have not been approved alter the braking efficiency.

Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings. If brake linings are used that differ from the original equipment, compliance with the original homologation is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the warranty shall be void.

- Only use brake linings approved and recommended by KTM.

Note

Environmental hazard Hazardous substances cause environmental damage.

- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info

Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.

Only use clean brake fluid from a sealed container.

Technical diagram showing three labeled mechanical components with numbered annotations

• Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
• Remove screws 1.
• Take off cover② with membrane③.
• Manually press the brake caliper toward the brake disc to push back the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, if necessary extract excess.

E00344-10

Info

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

• Remove cotter pin④, pull out pin⑤, and remove the brake linings.
• Clean the brake caliper and the brake caliper bracket.

Technical diagram showing mechanical assembly steps with numbered components and reference number 100397-01

- Check that spring plat⑥ in the brake caliper and sliding plate⑦ in the brake caliper bracket are seated correctly.

Close-up of a motorcycle brake system with visible caliper and suspension components (no text or symbols)

- Insert the new brake linings, insert the pin, and mount the cotter pins.

Info

Always change the brake linings in pairs.

- Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

Close-up of a mechanical component with a hand adjusting a tool, showing a labeled section A (no readable text or symbols beyond the label)

- Correct the brake fluid quantity to leA.

Guideline

Level A (brake fluid level below reservoir rim)

5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 (p. 143)

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

Info

Immediately clean up any brake fluid that has overflowed or spilled with water.

13.8 Checking the free travel of foot brake lever

Warning

Danger of accidents The brake system fails in the event of overheating.

If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.

- Set the free travel on the foot brake lever in accordance with the specification.

QUART 1 A 402026-10

• Disconnect spring①.
• 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.
  Guideline
  Free travel at foot brake lever 3 ... 5 mm (0.12 ... 0.2 in)
  » If the free travel does not meet specifications:
• Adjust the basic position of the foot brake lever. (p. 90)
• Reconnect spring①.

13.9 Adjusting the basic position of the foot brake level

Warning

Danger of accidents The brake system fails in the event of overheating.

If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.

- Set the free travel on the foot brake lever in accordance with the specification.

D ① A 402026-10

- Detach spring①.

Technical diagram of a mechanical assembly with numbered components, likely for assembly or maintenance reference.

• Loosen nut② and, with push roo③, turn it back until you have maximum free travel.
• To adjust the basic position of the foot brake lever to individual requirements, loosen nu④ and turn screw⑤ accordingly.

Info

The range of adjustment is limited.

- Turn push roo③ accordingly until you have free travA. If necessary, adjust the basic position of the foot brake lever.

Guideline

Free travel at foot brake lever 3 ... 5 mm (0.12 ... 0.2 in)

- Hold screw⑤ and tighten nut④.

Guideline

Nut, foot brake lever stop

M8 20 Nm (14.8 lbf ft)

- Hold push rod③ and tighten nut②.

Guideline

Remaining nuts, chassis

M6 10 Nm (7.4 lbf ft)

- Attach spring①.

13.10 Checking the rear brake fluid level

Warning

Danger of accidents An insufficient brake fluid level will cause the brake system to fail.

If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.

- Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)

Warning

Danger of accidents Old brake fluid reduces the braking effect.

- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)

① A S03518-10

• Stand the vehicle upright.
• Check the brake fluid level in the view①.

» If the fluid has dropped below mark A in the level viewer:

- Add rear brake fluid.(p. 91)

13.11 Adding rear brake fluid

Warning

Danger of accidents An insufficient brake fluid level will cause the brake system to fail.

If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.

- Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)

13 BRAKE SYSTEM

Warning

Skin irritation Brake fluid causes skin irritation.

• Keep brake fluid out of the reach of children.
• Wear suitable protective clothing and safety glasses.
• Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
• Consult a doctor immediately if brake fluid has been swallowed.
• Rinse the affected area with plenty of water in the event of contact with the skin.
• Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
• If brake fluid spills on to your clothing, change the clothing.

Warning

Danger of accidents Old brake fluid reduces the braking effect.

- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)

Note

Environmental hazard Hazardous substances cause environmental damage.

- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info

Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.

Only use clean brake fluid from a sealed container.

Technical diagram showing mechanical assembly steps labeled ① and ②, with component A highlighted in view.

Preparatory work

- Check the brake linings of the rear brake. (p. 93)

Main work

• Stand the vehicle upright.
• Remove screw cap① with membrane② and the O-ring.
• Add brake fluid to level A.

Brake fluid DOT 4 / DOT 5.1 ( p. 143)

- Mount and tighten the screw cap with the membrane and O-ring.

Info

Clean up overflowed or spilled brake fluid immediately with water.

13.12 Checking the brake linings of the rear brake

Warning

Danger of accidents Worn-out brake linings reduce the braking effect.

- Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.)

Mechanical assembly diagram showing a robotic arm with labeled component A and reference number E00349-10 (no readable text or symbols beyond labels)

- Check the brake linings for minimum thickness.

Minimum thickness A ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified: - Change the brake lingings of the rear brake. ( p. 93)

- Check the brake linings for damage and cracking.

» If damage or wear is encountered: - Change the brake lingings of the rear brake. ( p. 93)

←

13.13 Changing the brake linings of the rear brake

Warning

Danger of accidents Incorrect servicing will cause the brake system to fail.

- Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.)

Warning

Skin irritation Brake fluid causes skin irritation.

• Keep brake fluid out of the reach of children.
• Wear suitable protective clothing and safety glasses.
• Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
• Consult a doctor immediately if brake fluid has been swallowed.
• Rinse the affected area with plenty of water in the event of contact with the skin.
• Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
• If brake fluid spills on to your clothing, change the clothing.

Warning

Danger of accidents Old brake fluid reduces the braking effect.

- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)

Warning

Danger of accidents Brake linings which have not been approved alter the braking efficiency.

Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings. If brake linings are used that differ from the original equipment, compliance with the original homologation is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the warranty shall be void.

- Only use brake linings approved and recommended by KTM.

13 BRAKE SYSTEM

Note

Environmental hazard Hazardous substances cause environmental damage.

- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info

Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.

Only use clean brake fluid from a sealed container.

① ② S03488-10

• Position the vehicle vertically.
• Remove screw cap① with membrane② and the O-ring.
• Press the brake piston back into the basic position and ensure that brake fluid does not flow out of the brake fluid reservoir; extract some if necessary.

Info

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

③ ③ ④ E00351-10

• Remove cotter pin③, pull out pin④, and remove the brake linings.
• Clean the brake caliper and the brake caliper bracket.

⑤ ⑥ E00352-10

- Check that spring plate ⑤ in the brake caliper and sliding plate ⑥ in the brake caliper bracket are seated correctly.

Close-up of a mechanical assembly with visible gears and levers (no text or symbols)

- Insert the new brake linings, insert the pin, and mount the cotter pins.

Info

Always change the brake linings in pairs.

- Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

Technical diagram showing mechanical assembly steps with labeled parts 1 and 2, and a close-up view of component A.

- Add brake fluid to level A.

Brake fluid DOT 4 / DOT 5.1 (p. 143)

- Mount screw cap① with membrane② and O-ring.

Info

Immediately clean up any brake fluid that has overflowed or spilled with water.

14.1 Removing the front wheel

Preparatory work

- Raise the motorcycle with a lift stand. (p. 56)

Main work

- Manually press the brake caliper toward the brake disc to push back the brake pistons.

Close-up of a bicycle wheel with visible brake calipers and suspension rings (no text or symbols)

Info

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

② ① ② V00364-10

• Loosen screw 1 by several rotations.
• Loosen screws ②.
• Press on screw 1 to push the wheel spindle out of the axle clamp.
• Remove screw 1.

Mechanical assembly diagram showing a linkage mechanism with a bracket and shaft (no text or symbols visible)

Warning

Danger of accidents Damaged brake discs reduce the braking effect.

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

- Hold the front wheel and remove the wheel spindle. Take the front wheel out of the fork.

Info

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

- Remove spacers③.

H00934-10

14.2 Installing the front wheel

Warning

Danger of accidents Oil or grease on the brake discs reduces the braking effect.

• Always keep the brake discs free of oil and grease.
• Clean the brake discs with brake cleaner when necessary.

1 A H00935-10

• Check the wheel bearing for damage and wear.
  » If the wheel bearing is damaged or worn:
• Change front wheel bearing.
• Clean and grease shaft seal ring and contact surface of the spacers.

Long-life grease (p. 145)

- Insert the spacers.

- Clean and grease the wheel spindle.

Long-life grease (p. 145)

• Position the front wheel and insert the wheel spindle.
  √ The brake linings are correctly positioned.

- Mount and tighten screw②.

Guideline

Screw, front wheel spindle

M20x1.5 35 Nm (25.8 lbf ft)

③ ② ③ V00364-11

• Operate the hand brake lever several times until the brake linings are seated correctly against the brake disc.
• Remove the motorcycle from the lift stand. (p. 56)
• Operate the front brake and compress the fork a few times firmly.

√ The fork legs straighten.

- Tighten screws ③.

Guideline

Screw, fork stub M8 15 Nm (11.1 lbf ft)

14.3 Removing the rear wheel

Preparatory work

- Raise the motorcycle with a lift stand. (p. 56)

Technical diagram showing three labeled mechanical components of a bicycle gear assembly, with numbered annotations and a page number V00366-10 at the bottom.

Main work

- Manually press the brake caliper toward the brake disc to push back the brake piston.

Info

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

• Remove nut 1.
• Take off chain adjuste②. Pull out wheel spindle③ far enough to allow the rear wheel to be pushed forward.
• Push the rear wheel forward as far as possible. Remove the chain from the rear sprocket.

Info

Cover the components to protect them against damage.

Warning

Danger of accidents Damaged brake discs reduce the braking effect.

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

- Hold the rear wheel and remove the wheel spindle. Take the rear wheel out of the link fork.

Info

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

- Remove spacers④.

H03002-10

14.4 Installing the rear wheel

Warning

Danger of accidents Oil or grease on the brake discs reduces the braking effect.

• Always keep the brake discs free of oil and grease.
• Clean the brake discs with brake cleaner when necessary.

① A ① A H03001-10

Mechanical gear assembly diagram showing interlocking gears and chains (no text or symbols)

Diagram of bicycle gear assembly with numbered components labeled 3, 4, and 5

Mechanical gear assembly with numbered components (no visible text or symbols)

Main work

- Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:

- Change the rear wheel bearing.

- Clean and grease shaft seal ring and contact surface of the spacers.

Long-life grease ( p. 145)

- Insert the spacers.

- Clean and grease the wheel spindle.

Long-life grease ( p. 145)

- Position rear wheel and insert wheel spine?

√ The brake linings are correctly positioned.

- Mount the chain.

- Position chain adjuster③. Mount nut④, but do not tighten it yet.

- Make sure that chain adjuster③ are fitted correctly on adjusting screws⑤.

- Check the chain tension. ( p. 74)

- Tighten nut 4.

Guideline

Nut, rear wheel spin-dle

M20x1.5 80 Nm (59 lbf ft)

Info

The wide adjustment range of the chain adjusters (32 mm (1.26 in)) enables different secondary ratios with the same chain length.

Chain adjusters ③ can be turned by 180°.

- Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

Finishing work

- Remove the motorcycle from the lift stand. ( p. 56)

14.5 Checking the tire condition

Info

Only mount tires approved and/or recommended by KTM.

Other tires could have a negative effect on handling characteristics.

The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcycle.

Worn tires have a negative effect on handling characteristics, especially on wet surfaces.

Simple line drawing of an eye and a curved surface with a starburst symbol (no text or labels)

- Check the front and rear tires for cuts, embedded objects, and other damage.

» If the tires have cuts, run-in objects, or other damage:

- Change the tires.

- Check the tread depth.

Info

Adhere to the legally required minimum tread depth.

Minimum tread depth ≥ 2 mm (≥ 0.08 in)

» If the tread depth is less than the minimum tread depth:

- Change the tires.

- Check the tire age.

DOT EB CV 0208 1215 H01144-01

Info

The tire date of manufacture is usually contained in the tire label and is indicated by the last four digits of the DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manufacture.

KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear.

» If the tires are more than 5 years old:

- Change the tires.

14.6 Checking tire pressure

Info

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

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

Line drawing of a pressure gauge attached to a coiled tube, no text or symbols present

- Remove protection cap.

- Check tire pressure when the tires are cold.

Street tire pressure
front 1.5 bar (22 psi)
rear 1.5 bar (22 psi)
Offroad tire pressure
front 1.0 bar (15 psi)

rear 1.0 bar (15 psi)

» If the tire pressure does not meet specifications:

- Correct tire pressure.

- Mount the protection cap.

14.7 Checking spoke tension

Warning

Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage.

The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low, then lateral and radial run-out will form in the wheel. Other spokes will become looser as a result.

- Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.)

Line drawing of a bicycle wheel with a hand holding a tool, showing a musical note and number 400694-01 (no text or symbols on the diagram itself)

- Strike each spoke briefly using a screwdriver blade.

Info

The frequency of the sound depends on the spoke length and spoke diameter.

If you hear different tone frequencies from different spokes of equal length and diameter, this is an indication of different spoke tensions.

You should hear a high note.

» If the spoke tension differs:

- Correct the spoke tension.

- Check the spoke torque.

Guideline

Spoke nipple, front wheel	M4.5 5 Nm (3.7 lbf ft)
Spoke nipple, rear wheel	M4.5 5 Nm (3.7 lbf ft)

Torque wrench kit (58429094000)

15.1 Removing the 12-V battery

Note

Environmental hazard 12 V batteries contain environmentally hazardous materials.

• Do not dispose of 12 V batteries as household waste.
• Dispose of 12 V batteries at a collection point for used batteries.

Note

Environmental hazard Hazardous substances cause environmental damage.

- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Preparatory work

• Press and hold the switch-off button while the engine is idling until the engine stops.
• Remove the seat. ( p. 66)

Main work

① ② ③ ④ F00138-10

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

• Keep 12 V batteries out of the reach of children.
• Wear suitable protective clothing and safety glasses.
• Avoid contact with battery acid and battery gases.
• Keep sparks or open flames away from the 12 V battery.
• Only charge 12 V batteries in well-ventilated rooms.
• Rinse the affected area immediately with plenty of water in the event of contact with the skin.

• Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and battery gases get into the eyes.

• Disconnect negative cable ^1 from the 12-V battery.

• Pull back positive terminal cove② and disconnect the positive cable from the 12-V battery.
• Remove screw ③
• Pull holding bracket④ forward and remove the 12-V battery upwards.

4

15.2 Installing the 12-V battery

① ② ③ ④ ⑦ ⑤ ⑥ A H00386-10

Main work

- Insert the 12-V battery into the battery compartment with the terminals facing forward and secure with holding brac①t.

12-V battery (YTX5L-BS) (p. 139)

- Mount and tighten screw②.

Guideline

Remaining screws, chassis

M6 10 Nm (7)

4 lbf ft)

- Connect positive cable③ to the 12-V battery.

Guideline

Screw, battery terminal

M5 2.5 Nm

(1.84 lbf ft)

Contact disk A must be mounted under scre 5 and cable lug 6 with the claws toward the battery terminal.

- Slide positive terminal cove7 over the positive terminal.

- Connect negative cable ^4 to the 12-V battery.

Guideline

Screw, battery terminal

M5 2.5 Nm

(1.84 lbf ft)

Contact disk A must be mounted under scre 5 and cable lug 6 with the claws toward the battery terminal.

Finishing work

- Mount the seat. (p. 66)

15.3 Charging the 12-V battery

Note

Environmental hazard 12 V batteries contain environmentally hazardous materials.

• Do not dispose of 12 V batteries as household waste.
• Dispose of 12 V batteries at a collection point for used batteries.

Note

Environmental hazard Hazardous substances cause environmental damage.

- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info

Even if there is no load on the 12-V battery, it discharges each day. The charging level and the method of charging are very important for the service life of the 12-V battery. Rapid recharging with a high charging current shortens the service life of the battery. If the 12-V battery is depleted by repeated starting, the 12-V battery must be charged immediately.

Preparatory work

- Press and hold the switch-off button while the engine is idling until the engine stops.

White-brick electric 400240-10

• Remove the seat. (p. 66)
• Remove the 12-V battery.(p. 102)

Main work

Warning

Risk of injury Battery acid and battery gases cause serious chemical burns.

• Keep 12 V batteries out of the reach of children.
• Wear suitable protective clothing and safety glasses.
• Avoid contact with battery acid and battery gases.
• Keep sparks or open flames away from the 12 V battery.
• Only charge 12 V batteries in well-ventilated rooms.
• Rinse the affected area immediately with plenty of water in the event of contact with the skin.
• Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and battery gases get into the eyes.

- Connect a battery charger to the 12-V battery. Switch on the battery charger.

Battery charger (58429074000)

You can also use the battery charger to test the open-circuit voltage and starting ability of the 12-V battery, and to test the alternator. In addition, you cannot overcharge the 12-V battery with this device.

Info

If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. This reduces the capacity of the 12-V battery.

If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged and sulfating occurs, destroying the battery.

The 12-V battery is maintenance-free. The acid level does not have to be checked.

Never remove cover①

Charge the 12-V battery to a maximum of 10% of the capacity specified on battery housing ^② .

- Switch off the battery charger after charging and disconnect it from the 12-V battery.

Guideline

The charging current, charging voltage, and charging time must not be exceeded.
Recharge the 12-V battery regularly when the motorcycle is not being used	3 months

Finishing work

• Install the 12-V battery.(p. 103)
• Mount the seat. (p. 66)

15.4 Changing the main fuse

Warning

Fire hazard Incorrect fuses overload the electrical system.

• Only use fuses with the required ampere value.
• Do not bypass or repair fuses.

Info

The main fuse protects all power consumers of the vehicle.

Preparatory work

• Press and hold the switch-off button while the engine is idling until the engine stops.
• Remove the seat. (p. 66)

Main work

- Pull starter relay ^1 from the holder.

Close-up of a car engine compartment with visible wiring and components (no text or symbols)

A ② ③ ④

Close-up of electronic components with wires and connectors (no visible text or symbols)

• Take off protection cap②.
• Remove faulty main fus③.

Info

A faulty fuse has a burned-out fuse w. A. A spare fuse 4 is located in the starter relay.

- Install a new main fuse.

Fuse (58011109110) (p. 139)

- Check that the electrical system is functioning properly.

Tip

Insert a spare fuse so that it is available if needed.

• Mount the protection caps.
• Mount the starter relay onto the holder and route the cable.

Finishing work

- Mount the seat. ( p. 66)

15.5 Removing the headlight mask with the headlight

Close-up of mechanical components with numbered annotations (1) and E00355-10 label, no readable text or symbols beyond labels.

• Detach the brake line and wiring harness from the headlight mask.
• Loosen rubber strap①. Slide the headlight mask up and swing it forward.

Close-up of a robotic vehicle's mechanical components, including a wheel and gear assembly, with no visible text or symbols.

- Detach plug-in connectors② and take off the headlight mask with the headlight.

15.6 Installing the headlight mask with the headlight

Close-up of a robotic vehicle's mechanical components, possibly a vehicle or robot, with no visible text or symbols.

Main work

- Join plug-in connectors①.

Close-up of mechanical components with numbered annotations (2) and E00355-11 label, no readable text or symbols beyond labels.

• Position the headlight mask and secure it with rubber straps ②.
  √ The holding lugs engage in the fender.
• Position the brake line and wiring harness in the brake line guide.

Finishing work

- Check the headlight setting. ( p. 108)

15.7 Changing the headlight bulb

Note

Damage to reflector Grease on the reflector reduces the light intensity.

Grease on the bulb will evaporate due to the heat and be deposited on the reflector.

• Clean and degrease the bulbs before mounting.
• Do not touch the bulbs with your bare hands.

Close-up of a mechanical component with numbered parts, no visible text or symbols

Preparatory work

- Remove the headlight mask with the headlight. ( p. 106)

Main work

• Turn protection cap① together with the underlying bulb socket counterclockwise all the way and remove it.
• Pull bulb socket② of the position light out of the reflector.

③ ④ E00359-10

• Pull out headlight bull③.
• Insert the new headlight bulb.

Headlight (HS1/socket BX43t) (p. 139)

- Insert the protection cap with the bulb socket into the reflector and turn it clockwise all the way.

Info

Ensure that O-ring4 is seated properly.

- Insert the bulb socket of the position light into the reflector.

Finishing work

• Install the headlight mask with the headlight. (p. 106)
• Check the headlight setting. (p. 108)

15.8 Changing the turn signal bulb

Note

Damage to reflector Grease on the reflector reduces the light intensity.

Grease on the bulb will evaporate due to the heat and be deposited on the reflector.

• Clean and degrease the bulbs before mounting.
• Do not touch the bulbs with your bare hands.

Two views of a transparent optical lens with internal components, showing close-up and dissection (no text or symbols visible)

Main work

• Remove the screw on the rear of the turn signal housing.
• Carefully remove turn signal glas①.
• Lightly squeeze orange cap② in the area of the holding lugs and take it off.
• Press the turn signal bulb lightly into the socket, turn it counterclockwise by about 30°, and take it out of the socket.

Info

Do not touch the reflector with your fingers and keep it free from grease.

- Press the new turn signal bulb carefully into the socket and turn it clockwise until it stops.

Turn signal (R10W / socket BA15s) ( p. 139)

• Mount the orange cap.
• Position the turn signal glass.
• Insert the screw and first turn counterclockwise until it engages in the thread with a small jerk. Tighten the screw lightly.

Finishing work

- Check that the turn signal system is functioning properly.

15.9 Checking the headlight setting

A B 400726-10

• Park the vehicle on a horizontal surface in front of a light-colored wall and make a mark at the height of the center of the low beam headlight.
• Make another mark at a distance under the first marking. Guideline

Distance B 5 cm (2 in)

- Position the vehicle vertically at a distance away from the wall.

Guideline

Distance A 5 m (16 ft)

• The rider now sits down on the motorcycle.
• Switch on the low beam.
• Check the headlight setting.

The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider.

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

- Adjust the headlight range. (p. 109)

15.10 Adjusting the headlight range

Close-up of a mechanical assembly with numbered component (1) and label V00369-10, no readable text or symbols beyond the label.

Preparatory work

- Check the headlight setting. (p. 108)

Main work

- Loosen screw①.

- Adjust the headlight range by pivoting the headlight. Guideline

The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider (instructions on how to apply the mark: Checking the headlight setting).

Info

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

- Tighten screw 1.

15.11 Changing the combination instrument battery

Close-up of mechanical components with wires and connectors (no visible text or symbols)

Preparatory work

- Remove the headlight mask with the headlight. ( p. 106)

Main work

- Remove screws①.

– Pull the combination instrument upward out of the holder.

② ③ V00371-10

- Using a coin, turn protection c② all the way counterclockwise and take it off.

- Remove combination instrument batter ^3 .

- Insert the combination instrument with the label facing upward.

Combination instrument battery (CR 2430) (p. 139)

- Check the O-ring of the protection cap for correct seating.

Close-up of a mechanical component with a dial indicator and numbered annotation (no readable text or symbols)

- Position protection cap② and turn all the way clockwise using a coin.

- Press any button on the combination instrument.

√ The combination instrument is activated.

- Position the combination instrument in the holder.

- Mount and tighten the screws with washers.

• Install the headlight mask with the headlight. (p. 106)
• Check the headlight setting. (p. 108)
• Set the kilometers or miles. (p. 22)
• Adjust combination instrument function. (p. 23)
• Set the clock. (p. 24)

16.1 Cooling system

Close-up mechanical assembly showing a component with numbered callouts (1 and 2), no readable text or symbols present.

Water pump ^① in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator c _2 . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

120 °C (248 °F)

Cooling is effected by the air stream. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect.

16.2 Checking the antifreeze and coolant level

Warning

Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.

• Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
• Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
• In the event of scalding, rinse the area affected immediately with lukewarm water.

Warning

Danger of poisoning Coolant is toxic and a health hazard.

• Keep coolant out of the reach of children.
• Do not allow coolant to come into contact with the skin, the eyes and clothing.
• Consult a doctor immediately if coolant is swallowed.
• Rinse the affected area immediately with plenty of water in the event of contact with the skin.
• Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
• Change clothing if coolant spills onto your clothing.

A 400243-10

Condition

The engine is cold.

• Stand the motorcycle upright on a horizontal surface.
• Remove the radiator cap.
• Check the coolant antifreeze.

$$ - 2 5 \dots - 4 5 ^ {\circ} \mathrm{C} (- 1 3 \dots - 4 9 ^ {\circ} \mathrm{F}) $$

» If the antifreeze in the coolant does not match the specified value:
- Correct the coolant antifreeze.
- Check the coolant level in the radiator.

Coolant level A above the radiator fins

10 mm (0.39 in)

» If the coolant level does not match the specified value:

- Correct the coolant level.

Coolant ( p. 143)

- Mount the radiator cap.

◀

16.3 Checking the coolant level

Warning

Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.

• Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
• Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
• In the event of scalding, rinse the area affected immediately with lukewarm water.

Warning

Danger of poisoning Coolant is toxic and a health hazard.

• Keep coolant out of the reach of children.
• Do not allow coolant to come into contact with the skin, the eyes and clothing.
• Consult a doctor immediately if coolant is swallowed.
• Rinse the affected area immediately with plenty of water in the event of contact with the skin.
• Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
• Change clothing if coolant spills onto your clothing.

A 400243-10

Condition

The engine is cold.

• Stand the motorcycle upright on a horizontal surface.
• Remove the radiator cap.
• Check the coolant level in the radiator.

Coolant levelAabove the radiator fins

10 mm (0.39 in)

» If the coolant level does not match the specified value:
- Correct the coolant level.

Coolant ( p. 143)

- Mount the radiator cap.

16.4 Draining the coolant

Warning

Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.

• Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
• Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
• In the event of scalding, rinse the area affected immediately with lukewarm water.

Warning

Danger of poisoning Coolant is toxic and a health hazard.

• Keep coolant out of the reach of children.
• Do not allow coolant to come into contact with the skin, the eyes and clothing.
• Consult a doctor immediately if coolant is swallowed.
• Rinse the affected area immediately with plenty of water in the event of contact with the skin.
• Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
• Change clothing if coolant spills onto your clothing.

Condition

The engine is cold.

• Position the motorcycle upright.
• Place an appropriate container under the water pump cover.
• Remove screw①. Take off radiator ca②.
• Completely drain the coolant.
• Mount and tighten screw with a new seal ring.

Guideline

Screw, water pump cover

M6 10 Nm (7.4 lbf ft)

Close-up mechanical assembly showing a component with numbered callouts (1 and 2), no readable text or symbols present.

16.5 Refilling with coolant

Warning

Danger of poisoning Coolant is toxic and a health hazard.

• Keep coolant out of the reach of children.
• Do not allow coolant to come into contact with the skin, the eyes and clothing.
• Consult a doctor immediately if coolant is swallowed.
• Rinse the affected area immediately with plenty of water in the event of contact with the skin.
• Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
• Change clothing if coolant spills onto your clothing.

Close-up of a motorcycle's internal mechanical component, showing gears and a labeled part (no readable text or symbols)

Main work

• Make sure that screw 1 is tightened.
• Position the motorcycle upright.

16 COOLING SYSTEM

Mechanical assembly with numbered component (2) and no visible text or symbols

Close-up of a mechanical component with wires and a labeled part (3), no readable text or symbols present.

• Loosen screw ^2 and wait until coolant escapes without bubbles.
• Mount and tighten screw②.

Guideline

Bleeder screw, cylinder head

M6 10 Nm (7.4 lbf ft)

- Completely fill the radiator with coolant.

Coolant ( p. 143)

- Mount radiator cap③.

Danger

Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

• Always make sure there is sufficient ventilation when running the engine.
• Use effective exhaust extraction when starting or running the engine in an enclosed space.

- Allow the engine to warm up and cool down again.

Finishing work

- Check the coolant level. (p. 112)

17.1 Checking the throttle cable play

3D rendered mechanical part with circular arrows indicating rotation or movement, no text or symbols present

• Check the throttle grip for smooth operation.
• Turn handlebar as far as possible to the right. Turn the throttle grip back and forth slightly and determine the play in the throttle cable.

Throttle cable play 3 ... 5 mm (0.12 ... 0.2 in)

» If the throttle cable play does not meet specifications:

- Adjust the throttle cable play (p. 115)

Danger

Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

• Always make sure there is sufficient ventilation when running the engine.
• Use effective exhaust extraction when starting or running the engine in an enclosed space.

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

The idle speed must not change.

» If the idle speed changes:
- Adjust the throttle cable play. (p. 115)

17.2 Adjusting the throttle cable play

Info

If the correct routing of the throttle cable has already been secured, the fuel tank does not need to be removed.

Preparatory work

• Remove the seat. (p. 66)
• Remove the fuel tank.(p. 71)
• Check throttle cable routing. (p. 79)

17 TUNING THE ENGINE

Technical diagram showing mechanical components and a labeled mechanical component with rotational arrows

Main work

• Turn handlebar as far as possible to the right.
• Push back sleeve①.
• Ensure that the throttle cable sleeve is pushed all the way into barrel adjuster ②.
• Loosen nut③.
• Turn barrel adjuster② so that there is plaA in the throttle cable at the throttle grip.

Guideline

Throttle cable play 3 ... 5 mm (0.12 ... 0.2 in)

• Tighten nut③.
• Slide on sleeve①.

Finishing work

• Check the throttle grip for smooth operation.
• Install the fuel tank. (p. 72)
• Mount the seat. (p. 66)
• Check the throttle cable play. (p. 115)

17.3 Carburetor tuning

Effects of carburetor tuning

The different carburetor components must be tuned both to one another and for the use intended.

Main jet MJ

The main jet MJ has the greatest influence with the throttle slide open (full throttle).

If the insulator of a new spark plug is very light or white after a brief ride at full throttle, or if the engine knocks, a larger main jet needs to be used. If the insulator is dark brown or sooty, a smaller main jet needs to be used.

Needle position POS

The needle position has the greatest influence in the mid throttle slide range.

If the engine stutters when accelerating with a partially open throttle slide, the jet needle must be lowered. If the engine knocks when accelerating at the full power rpm range, the jet needle must be raised.

Cylindrical part of the needle CYL

The cylindrical part of the needle has the greatest influence when the throttle slide is almost closed.

Idling jet IJ

The idling jet has the greatest influence in the low to mid throttle slide range.

If the engine stutters at idle speed or when accelerating with a partially open throttle slide, a smaller idling jet must be used. If the engine knocks in this power range, then a larger idling jet must be used.

Idle air adjusting screw open ASO

The idle air adjusting screw has the greatest influence at idle speed.

Influence of throttle slide adjustment

1 3/4 1/2 1/4 1/8 0 1 3/4 1/2 1/4 1/8 0 K00495-01

The idling jet has the greatest influence when the throttle slide is closed. The first cylindrical part of the needle and the clip position have only minimal influence.

When the throttle slide is 1/8 open, the first cylindrical part of the needle, the idling jet and the clip position have the greatest influence.

1 3/4 1/2 1/4 1/8 0 1 3/4 1/2 1/4 1/8 0 K00496-01

When the throttle slide is 1/4 open, the idling jet and the clip position have the greatest influence. The influence of the first cylindrical part of the needle is less.

When the throttle slide is 1/2 open, the position of the needle has the greatest influence. The influence of the main jet and the idling jet is only minimal.

17 TUNING THE ENGINE

K00497-01

When the throttle slide is 3/4 open, the influence of the main jet is greatest. The clip position and the idling jet have only minimal influence.

When the throttle slide is fully open, the influence of the main jet is greatest. The clip position and the idling jet have only minimal influence.

Needle overview

The jet needles available are shown in the following table.

	1	2	3	4
A	6BFY42-71	6BFY43-71	6BFY44-71	2,71 mm
B	6BFY42-72	6BFY43-72	6BFY44-72	2.72 mm
C	6BFY42-73	6BFY43-73	6BFY44-73	2.73 mm
D	6BFY42-74	6BFY43-74	6BFY44-74	2.74 mm
E	6BFY42-75	6BFY43-75	6BFY44-75	2.75 mm
F	6BFY42-76	6BFY43-76	6BFY44-76	2.76 mm

Column 2 corresponds to a needle in the standard position.

Column 1 corresponds to a needle which is half a clip leaner.

Column 3 corresponds to a needle which is half a clip richer.

Column 4 specifies the diameter of the first cylindrical part of the needle. The smaller the diameter of the first cylindrical part of the needle, the richer the mixture preparation. The larger the diameter of the first cylindrical part of the needle, the leaner the mixture preparation. The first cylindrical part of the needle has the greatest influence in the lowest load range.

Info

The top right jet needle A3 corresponds to the richest setting of the carburetor, and the bottom left jet needle F1 corresponds to the leanest. The optimal carburetor tuning is shown under the respective model.

1 2 3 4 5 B00075-10

Clip position

1... 5 Clip position from above

The five possible clip positions are shown here.

The carburetor tuning depends on the defined ambient and operating conditions.

17.4 Carburettor - idle speed

① ② 402799-10

The idle setting of the carburetor has a big influence on the starting behavior, stable idle speed, and the response to throttle opening. This means that an engine with a correctly set idle speed will be easier to start than one with an incorrectly set idle speed.

Info

The carburetor and its components are subject to increased wear caused by engine vibration. Wear can result in malfunctioning.

The factory setting for the carburetor is set for the following values.

Height above sea level	751 ... 1,500 m (2,464 ... 4,921 ft)
Ambient temperature	16 ... 24 °C (61 ... 75 °F)

Super unleaded, type C (ROZ 95/RON 95/PON 91 mixed with 2-stroke engine oil, 1:60) ( p. 144)

The idle speed is adjusted with adjusting screw.

The idle mixture is adjusted using the idle air adjusting screw

17.5 Carburetor - adjusting the idle speed

② ① 402799-11

• Screw idle air adjusting scre① all the way in.
• Turn the idle air adjusting screw to the specified basic setting.

Info

The basic setting of the carburetor is specified in the technical data.

- Run the engine until warm. Guideline

Warming-up phase ≥ 5 min

- Connect the special tool.

Tachometer (45129075000)

Danger

Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

• Always make sure there is sufficient ventilation when running the engine.
• Use effective exhaust extraction when starting or running the engine in an enclosed space.

- Adjust the idle speed with adjusting scr?

Guideline

Choke function deactivated – The choke lever is pushed in to the stop. ( p. 19)
Idle speed 1,400 ... 1,500	rpm

• Turn idle air adjusting scre① slowly in a clockwise direction until the idle speed begins to fall.
• Note the position and turn the idle air adjusting screw slowly counterclockwise until the idle speed again begins to fall.
• Adjust to the point between these two positions with the highest idle speed.

Info

If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps.

If the procedure described here does not lead to satisfactory results, the cause may be a wrongly dimensioned idling jet.

If you can turn the idle air adjusting screw to the end without any change of engine speed, mount a smaller idling jet.

After changing the jet, start from the beginning with the adjusting steps.

Following extreme air temperature or altitude changes, adjust the idle speed again.

17.6 Ignition curve plug-in connector

Close-up of a motorcycle's front wheel assembly with visible mechanical components and no text or symbols

Plug-in connector 1 of the ignition timing map adjustment is located on the frame under the fuel tank.

Possible states

• Soft – The plug-in connector of the ignition timing map adjustment is disconnected to achieve better rideability.
• Performance – The plug-in connector of the ignition timing map adjustment is joined to achieve higher performance.

17.7 Changing the ignition timing map

Info

If the map switch (optional) is installed, the ignition timing map can be changed from the handlebar.

Switching the ignition timing map from Performance to Soft

- Disconnect plug-in connector of the ignition timing map adjustment. (Figure K01217-10 p. 120)

√ Soft – better rideability

Switching the ignition timing map from Soft to Performance

- Join plug-in connector of the ignition timing map adjustment. (Figure K01217-10 p. 120)

√ Performance – better performance

17.8 Checking the basic position of the shift lever

Info

When driving, the shift lever must not touch the rider's boot when in the basic position.

When the shift lever keeps touching the boot, the transmission will be subject to an excessive load.

A 400692-10

- Sit on the vehicle in the riding position and determine distance A between the upper edge of your boot and the shift lever.

Distance between shift lever and upper edge of boot

10 ... 20 mm (0.39 ... 0.79 in)

» If the distance does not meet specifications:

- Adjust the basic position of the shift lever. (p. 121)

17.9 Adjusting the basic position of the shift lever

2 1 401950-12

- Remove screw① with the washers and take off shift lever ②.

A 401951-10

- Clean gear teeth A of the shift lever and shift shaft.

- Mount the shift lever on the shift shaft in the required position and engage gearing.

Info

The range of adjustment is limited.

The shift lever must not come into contact with any other vehicle components during the shift procedure.

- Mount and tighten screw with the washers. Guideline

Screw, shift lever

M6 14 Nm (10.3 lbf ft)Loctite®243TM

17.10 Engine characteristic - auxiliary spring

B00056-10

The auxiliary spring is located on the right side of the engine below the water pump cover.

Possible states

• Auxiliary spring with green color coding – Auxiliary spring for soft performance.
• Auxiliary spring with yellow color coding – Auxiliary spring for more aggressive performance than with a green spring.
• Auxiliary spring with blue color coding – Auxiliary spring for more aggressive performance than with a yellow spring.
• Auxiliary spring with red color coding – Auxiliary spring for more aggressive performance than with a blue spring.
• Auxiliary spring without color coding – Auxiliary spring for progressive performance (at first more aggressive than with the red spring, then softer than with the red spring).

The engine characteristic can be influenced by different spring strengths of auxiliary spring ^1 .

Info

The auxiliary spring mounted in the as-delivered state as well as the additionally available auxiliary springs can differ depending on model.

17.11 Engine characteristic - adjusting the auxiliary spring

Warning

Danger of burns Some vehicle components become very hot when the vehicle is operated.

• Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have cooled down.
• Let the vehicle parts cool down before you perform any work on the vehicle.

Preparatory work

• Tilt the motorcycle to the left and secure against falling in this position.
  Guideline

Angle of title approx. 45°

Close-up mechanical assembly showing a motor and gear mechanism (no visible text or symbols)

Main work

- Remove screws 1.

② ③ ④ ⑤ B00056-11

• Remove cap②, adjusting spring③, auxiliary spring④, and spring insert⑤ from the clutch cover.
• Pull both springs off of the spring insert.
• Mount the required auxiliary spring ( p. 122④ and adjusting spring③ and position them together in the clutch cover.

Auxiliary spring with yellow marking (54637072300)

Auxiliary spring with green marking (54837072100)

Auxiliary spring with red marking (54837072000)

√ The recess in spring insert engages in the angle lever.

• Check the O-ring in the cap.
• Position the cap.
• Mount and tighten the screws.

Guideline

Screw, exhaust con-trol cap

M5 5 Nm (3.7

lbf ft)

Close-up mechanical component with numbered annotation (6) and identifier S03663-10, no readable text or symbols beyond the label.

- Check screw⑥ for correct setting measurement. Guideline

Exhaust control - setting measurement

2.3 ± 0.2 mm ( 0.091 ± 0.008 in)

◀

18.1 Emptying the carburetor float chamber

Danger

Fire hazard Fuel is highly flammable.

The fuel in the fuel tank expands when warm and can escape if overfilled.

• Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
• Switch off the engine for refueling.
• Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
• If any fuel is spilled, wipe it off immediately.
• Observe the specifications for refueling.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

• Avoid skin, eye and clothing contact with fuel.
• Immediately consult a doctor if you swallow fuel.
• Do not inhale fuel vapors.
• In case of skin contact, rinse the affected area with plenty of water.
• Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
• Change your clothing in case of fuel spills on them.
• Keep fuels correctly in a suitable canister, and out of the reach of children.

Note

Environmental hazard Improper handling of fuel is a danger to the environment.

- Do not allow fuel to enter the groundwater, the soil, or the sewage system.

Info

Carry out work with a cold engine.

Water in the float chamber results in malfunctioning.

Preparatory work

• Turn tap handle of the fuel tap to the OFF position.
  √ Fuel no longer flows from the fuel tank to the carburetor.

Close-up mechanical assembly showing hoses and components (no visible text or symbols)

Main work

• Place a cloth under the carburetor to capture the draining fuel.
• Remove screw plug①.
• Fully drain the fuel.
• Mount and tighten the screw plug.

18.2 Checking the gear oil level

Info

The gear oil level must be checked when the engine is cold.

Close-up mechanical assembly showing a gear and spring mechanism (no visible text or symbols)

Preparatory work

- Stand the motorcycle upright on a horizontal surface.

Main work

• Detach the foot brake lever spring.
• Remove gear oil level monitoring scre ^1 .
• Check the gear oil level.

A small quantity of gear oil must run out of the drilled hole.

» If no gear oil runs out:

- Add the gear oil (p. 126)

- Mount and tighten the gear oil level monitoring screw. Guideline

Screw, gear oil level monitoring

M6 10 Nm (7.4 lbf ft)

- Attach the foot brake lever spring.

18.3 Changing the gear oil

Warning

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

• Wear suitable protective clothing and safety gloves.
• In the event of scalding, rinse the area affected immediately with lukewarm water.

Note

Environmental hazard Hazardous substances cause environmental damage.

- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info

Drain the gear oil while the engine is at operating temperature.

Mechanical assembly diagram showing a chain and gear mechanism (no text or symbols visible)

Preparatory work

• Park the motorcycle on a level surface.
• Place an appropriate container under the engine.

Main work

• Remove gear oil drain plu① with magnet.
• Let the gear oil drain fully.
• Thoroughly clean the gear oil drain plug with magnet.
• Clean the sealing surface on the engine.
• Mount and tighten gear oil drain p with the magnet and a new seal ring.

② 401955-11

Guideline

Gear oil drain plug with magnet

M12x1.5 20 Nm (14.8 lbf ft)

- Remove filler plug② with the O-ring, and fill up with gear oil.

Gear oil 0.80 l

(0.85 qt.)

Engine oil(15W/50)(p. 143)

- Mount and tighten the filler plug together with the O-ring.

Danger

Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

• Always make sure there is sufficient ventilation when running the engine.
• Use effective exhaust extraction when starting or running the engine in an enclosed space.

- Start the engine and check for tightness.

Finishing work

- Check the gear oil level. (p. 125)

18.4 Adding the gear oil

Info

Too little gear oil or poor-quality gear oil results in premature wear to the transmission. Gear oil must only be topped up when the engine is cold.

Preparatory work

- Park the motorcycle on a level surface.

Main work

- Remove gear oil level monitoring scre ^1 .

Close-up of a mechanical assembly with numbered component (1) and no visible text or symbols

② 401955-11

• Remove filler plug② with the O-ring.
• Add gear oil until it emerges from the drill hole of the gear oil level monitoring screw.

Engine oil (15W/50) (p. 143)

- Mount and tighten the gear oil level monitoring screw. Guideline

Screw, gear oil level monitoring

M6 10 Nm (7)

4 lbf ft)

- Mount and tighten filler plu② with the O-ring.

Danger

Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

• Always make sure there is sufficient ventilation when running the engine.
• Use effective exhaust extraction when starting or running the engine in an enclosed space.

- Start the engine and check for tightness.

Finishing work

- Check the gear oil level. (p. 125)

19.1 Cleaning the motorcycle

Note

Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly.

The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components.

• Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
• Maintain a minimum distance between the nozzle of the pressure cleaner and the component. Minimum clearance 60 cm (23.6 in)

Note

Environmental hazard Hazardous substances cause environmental damage.

- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info

To maintain the value and appearance of the motorcycle over a long period, clean it regularly. Avoid direct sunshine when cleaning the motorcycle.

Diagram showing a motor spraying water onto a scooter with a brush, no text or symbols present

• Close off the exhaust system to keep water from entering.
• Remove coarse dirt particles with a gentle water jet.
• Spray heavily soiled parts with a normal commercial motorcycle cleaner and then brush off with a soft brush.

Motorcycle cleaner ( p. 145)

Info

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

Never apply motorcycle cleaner to a dry vehicle; always rinse the vehicle with water first.

• After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly.
• Empty the carburetor float chamber. (p. 124)
• Remove the closure of the exhaust system.

Warning

Danger of accidents Moisture and dirt impair the brake system.

- Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs.

- After cleaning, ride the vehicle a short distance until the engine warms up.

Info

The heat produced causes water at inaccessible locations in the engine and on the brake system to evaporate.

• After the motorcycle has cooled down, lubricate all moving parts and pivot points.
• Clean the chain. (p. 74)
• Treat bare metal (except for brake discs and the exhaust system) with a corrosion inhibitor.

Preserving materials for paints, metal and rubber (p. 145)

- Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

Special cleaner for glossy and matte paint finishes, metal and plastic surfaces (p. 146)

- Oil the steering lock.

Universal oil spray ( p. 146)

19.2 Checks and maintenance steps for winter operation

Info

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

If the vehicle has been used on salted roads, use cold water for cleaning after riding. Warm water enhances the corrosive effects of salt.

Simple line drawing of a person riding a bicycle with snowflake patterns falling around (no text or symbols)

• Clean the motorcycle. (p. 128)
• Clean the brakes.

Info

After EVERY trip on salted roads, thoroughly clean the brake calipers and brake linings, after they have cooled down and without removing them, with cold water and dry them carefully.

After riding on salted roads, thoroughly clean the vehicle with cold water and dry it well.

- Treat engine, link fork, and all other bare or zinc-plated parts (except the brake discs) with a wax-based corrosion inhibitor.

Info

Corrosion inhibitor must not come in contact with the brake discs as this would greatly reduce the braking force.

- Clean the chain. (p. 74)

20.1 Storage

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

• Avoid skin, eye and clothing contact with fuel.
• Immediately consult a doctor if you swallow fuel.
• Do not inhale fuel vapors.
• In case of skin contact, rinse the affected area with plenty of water.
• Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
• Change your clothing in case of fuel spills on them.
• Keep fuels correctly in a suitable canister, and out of the reach of children.

Info

If you plan to garage the motorcycle for a longer period, perform the following steps or have them performed.

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.

Simple line drawing of a motorcycle under a roof, with no text or symbols present.

• Clean the motorcycle. (p. 128)
• Change the gear oil. (p. 125)
• Check the antifreeze and coolant level. (p. 111)
• When refueling for the last time before taking the motorcycle out of service, add fuel additive.

Fuel additive (p. 145)

• Refuel. (p. 43)
• Empty the carburetor float chamber. (p. 124)
• Check tire pressure. (p. 100)
• Remove the 12-V battery.(p. 102)
• Charge the 12-V battery. (p. 103)

Guideline

Storage temperature of the 12-V battery without direct sunlight

0 ... 35 °C (32 ... 95 °F)

- Store the vehicle in a dry location that is not subject to large fluctuations in temperature.

Info

KTM recommends jacking up the motorcycle.

• Raise the motorcycle with a lift stand. (p. 56)
• Cover the vehicle with a tarp or a similar cover that is permeable to air.

Info

Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Because the engine will not warm up sufficiently, the water vapor produced during combustion will condense, causing engine parts and the exhaust system to rust.

20.2 Preparing for use after storage

Simple line drawing of a motorcycle and a house with directional arrows (no text or symbols)

• Remove the motorcycle from the lift stand. (p. 56)
• Install the 12-V battery.(p. 103)
• Perform checks and maintenance measures when preparing for use. (p. 40)
• Make a test ride.

21 TROUBLESHOOTING

Faults Possible cause Action
The engine cannot be cranked (starter motor)	Operating error - Carry out start procedure. (p. 40)
	12-V battery discharged - Charge the 12-V battery. (p. 103)- Check the charging voltage- Check the closed current- Check the alternator.
	Main fuse is blown - Change the main fuse. (p. 105)
	Starter relay faulty - Check the starter relay.
	Starter motor faulty - Check the starter motor.
Engine turns but does not start	Operating error - Carry out start procedure. (p. 40)
	The motorcycle has been in dis- Empty the carburetor float chamberuse for an extended period and (p. 124)old fuel is in the float chamber
	Fuel feed interrupted - Check the fuel tank breather.- Clean the fuel tap.- Check/set the carburetor components.
	Spark plug oily or wet - Clean and dry the spark plug, orchange it if necessary.
	Plug gap of spark plug too wide - Adjust plug gap.GuidelineSpark plug electrode gap0.60 mm (0.0236 in)
	Fault in ignition system	- Check the ignition system.
	Short-circuit cable in wiring harness frayed, switch-off button faulty	- Check the switch-off button.
	The connector or ignition coil loose or oxidized	- Clean the connector and treat it with contact spray.
	Water in carburetor or jets blocked	- Check/set the carburetor components.
Engine has no idle speed	Idling jet blocked	- Check/set the carburetor components.
	Adjusting screws on carburetor distorted	- Carburetor - adjust the idle speed. (p. 119)
	Spark plug defective	- Change the spark plug.
	Ignition system defective	- Check the ignition coil- Check the spark plug connector.
Engine does not speed up	Carburetor running over because float needle dirty or worn	- Check/set the carburetor components.
	Loose carburetor jets	- Check/set the carburetor components.
	Fault in ignition system	- Check the ignition system.
Engine has too little power	Fuel feed interrupted	- Check the fuel tank breather.- Clean the fuel tap.- Check/set the carburetor components.
	Air filter very dirty	- Clean the air filter and air filter box. (p. 69)
Engine has too little power Exhaust system leaky, deformed or too little glass fiber yarn filling in main silencer		- Check exhaust system for damage.- Change the glass fiber yarn filling in the main silencer. (p. 70)
		Fault in ignition system - Check the ignition system.
		Diaphragm or reed valve housing damaged
Engine stalls or is popping into the carburetor	Lack of fuel - Turn tap handle of the fuel tap to the ON position.- Refuel. (p. 43)
	Engine takes in bad air - Check the intake flange and carburetor for tightness.
	The connector or ignition coil loose or oxidized	- Clean the connector and treat it with contact spray.
Engine overheats Too little coolant in cooling system		- Check the cooling system for leakage.- Check the coolant level. (p. 112)
		Too little air stream - Switch off engine when stationary.
		Radiator fins very dirty
		Foam formation in cooling system
		Damaged cylinder head or cylinder head gasket
		Bent radiator hose
		Incorrect ignition point due to loose stator
White smoke emission (steam in exhaust gas)	Damaged cylinder head or cylinder head gasket	- Check the cylinder head and cylinder head gasket.
Gear oil exits at the vent hose	Too much gear oil added	- Check the gear oil level. (p. 125)
Water in the gear oil	Damaged shaft seal ring or water pump	- Check the shaft seal ring and water pump.

22.1 Engine

Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control
Displacement 293.15 cm3 (17.8892 cu in)
Stroke 72 mm (2.83 in)
Hole 72 mm (2.83 in)
Idle speed 1,400 ... 1,500 rpm
Exhaust control - setting measurement 2.3	-0.2mm (0.091+0.008in)
Crankshaft bearing 1 grooved ball bearing/1 roller bearing
Conrod bearing Needle bearing
Piston pin bearing Needle bearing
Piston	Cast aluminum
Piston rings	2 rectangular rings
Engine lubrication	Mixed lubrication
X distance (upper edge of piston to upper edge of cylinder)	0 ... 0.10 mm (0 ... 0.0039 in)
Z distance (height of control flap)	49.5 mm (1.949 in)
Primary transmission	26:73
Clutch	Multidisc clutch in oil bath/hydraulically activated
Transmission	6-gear transmission, claw shifted
Transmission ratio
first-gear	14:32
second-gear	16:26
third-gear	20:25
fourth-gear	22:23
fifth-gear	25:22
sixth-gear	26:20
Alternator	12 V, 110 W
Ignition system	Contactless controlled fully electronic ignition with digital ignition adjustment
Spark plug	NGK BR 7 ES
Spark plug electrode gap	0.60 mm (0.0236 in)
Cooling	Water cooling, permanent circulation of coolant by water pump
Starting aid	Electric starter system

22.2 Engine tightening torques

Screw, inner membrane sheets	EJOTDELTA PT35x25	1 Nm (0.7 lbf ft)
Screw, membrane support plate	EJOTDELTA PT® 30x12	1 Nm (0.7 lbf ft)
Screw, outer membrane sheets	EJOTDELTA PT30x6	1 Nm (0.7 lbf ft)
Screw, angle lever, exhaust control	M5	6 Nm (4.4 lbf ft)Loctite®243TM
Screw, bearing retainer	M5	6 Nm (4.4 lbf ft)Loctite®243TM
Screw, clutch spring retainer	M5	6 Nm (4.4 lbf ft)
Screw, crankshaft speed sensor M5 6 Nm (4.4 lbf ft)		Loctite®243TM
Screw, exhaust control bearing support	M5 6 Nm (4.4 lbf ft)	Loctite®243TM
Screw, exhaust control cap M5 5	Nm (3.7 lbf ft)
Screw, exhaust control cover M5 4	Nm (3 lbf ft)
Screw, locking lever M5 6 Nm (4.4 lbf ft)		Loctite®243TM
Screw, retaining bracket of exhaust control	M5 6 Nm (4.4 lbf ft)	Loctite®2701TM
Bleeder screw, cylinder head M6	10 Nm (7.4 lbf ft)
Nut, water pump impeller M6 5	Nm (3.7 lbf ft)	Loctite®243TM
Screw, alternator cover M6 8 Nm	(5.9 lbf ft)
Screw, clutch slave cylinder M6 10	Nm (7.4 lbf ft)
Screw, control flap, exhaust control	M6 8 Nm (5.9 lbf ft)	Loctite®243TM
Screw, engine case M6 10 Nm (7.4 lbf ft)
Screw, exhaust control thrust bearing	M6 8 Nm (5.9 lbf ft)	Loctite®243TM
Screw, exhaust flange M6 8 Nm	(5.9 lbf ft)
Screw, gear oil level monitoring M6	10 Nm (7.4 lbf ft)
Screw, intake flange/reed valve housing	M6 6 Nm (4.4 lbf ft)
Screw, intermediate clutch cover	M6 10 Nm (7.4 lbf ft)
Screw, outer clutch cover	M6 8 Nm (5.9 lbf ft)
Screw, shift drum locating	M6 10 Nm (7.4 lbf ft)	Loctite®243TM
Screw, shift lever	M6 14 Nm (10.3 lbf ft)	Loctite®243TM
Screw, starter motor	M6 10 Nm (7.4 lbf ft)
Screw, starter motor bearing bush	M6 10 Nm (7.4 lbf ft)	Loctite®243TM
Screw, starter motor protection cap	M6 8 Nm (5.9 lbf ft)
Screw, stator	M6 10 Nm (7.4 lbf ft)	Loctite®243TM
Screw, water pump cover	M6 10 Nm (7.4 lbf ft)
Vacuum connection, housing breather	M6 2 Nm (1.5 lbf ft)
Screw, balancer shaft	M8 30 Nm (22.1 lbf ft)	Loctite®243TM
Screw, cylinder head	M8 27 Nm (19.9 lbf ft)
Nut, cylinder base	M10	35 Nm (25.8 lbf ft)
Screw, drive chain engine sprocket	M10	60 Nm (44.3 lbf ft)Loctite®2701TM
Stud, cylinder base	M10	20 Nm (14.8 lbf ft)Lubricated with engine oil
Nut, rotor	M12x1	55 Nm (40.6 lbf ft)
Gear oil drain plug with magnet M12x1.5		20 Nm (14.8 lbf ft)

22 TECHNICAL DATA

Spark plug M14x1.25 25 Nm (18.4 lbf ft)
Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft)	Loctite® 648TM
Nut, primary gear wheel M18LHx1.5 150 Nm (110.6 lbf ft)	Loctite® 648TM

22.3 Carburetor

Carburetor type MIKUNI TMX 38
Carburetor identification number TMX 38 86
Needle position 3rd position from top
Jet needle 6BFY43-73 (6BFY42-73, 6BFY42-74, 6BFY43-74)
Main jet 470 (460, 480, 490)
Idling jet 35 (32.5/37.5/40)
Choke nozzle 80
Needle jet S-4
Idle air adjusting screw
Open 2 turns
Throttle slide 4

22.3.1 Carburetor tuning

MIKUNI TMX 38

ASL	TEMP	-20 ... -7 °C(-4 ... 19 °F)	-6 ... 5 °C(21 ...41 °F)	6 ... 15 °C(43 ...59 °F)	16 ... 24 °C(61 ...75 °F)	25 ... 36 °C(77 ...97 °F)	37 ... 49 °C(99 ...120 °F)
2,301 ...3,000 m(7,549 ...9,843 ft)	ASO	2.5	2.5	2	2	2
	IJ	32.5	30	32.5	30	30
	NDL	43-73	43-73	42-73	42-73	43-73
	POS	3	3	3	3	2
	MJ	470	460	460	450	450
1,501 ...2,300 m(4,925 ...7,546 ft)	ASO	2	2.5	2.5	2	2	2
	IJ	35	32.5	30	32.5	30	30
	NDL	43-73	43-73	43-73	42-73	42-73	43-73
	POS	3	3	3	3	3	2
	MJ	470	470	460	460	450	450
751 ...1,500 m(2,464 ...4,921 ft)	ASO	2	2	2.5	2.5	2	2
	IJ	35	35	32.5	30	32.5	30
	NDL	43-73	43-73	43-73	43-73	42-73	42-73
	POS	3	3	3	3	3	3
	MJ	480	470	470	460	460	450
301 ...750 m(988 ...2,461 ft)	ASO	2	2	2	2.5	2.5	2
	IJ	37.5	35	35	32.5	30	32.5
	NDL	43-73	43-73	43-73	43-73	43-73	42-73
	POS	3	3	3	3	3	3
	MJ	490	480	470	470	460	460
0 ...300 m (0... 984 ft)	ASO	2	2	2	2.5	2.5	2
	IJ	40	35	35	32.5	30	32.5
	NDL	43-73	43-73	43-73	43-73	43-73	42-73
	POS	3	3	3	3	3	3
	MJ	500	480	470	470	460	460

ASL	Sea level
TEMP	Temperature
ASO	Idle air adjusting screw open
IJ	Idling jet
NDL	Needle
POS	Needle position from top
MJ Main jet

Does not apply on sandy terrain.

22.4 Capacities

22.4.1 Gear oil

Gear oil 0.80 l (0.85 qt.) Engine

oil (15W/50) ( p. 143)

22.4.2 Coolant

Coolant 1.2 | (1.3 qt.) Coolant (

p. 143)

22.4.3 Fuel

Total fuel tank capacity, approx.

7.5 l (1.98 US gal) Super unleaded

type C (ROZ 95/RON 95/PON 91 mixed with 2-stroke engine oil, 1:60) (p. 144)

Fuel reserve, approx. 1.5 | (1.6 qt.)

22.5 Chassis

Frame Central tube frame made of chrome molybdenum steel tubing
Fork WP XPLOR 5348
Suspension travel
front	292 mm (11.5 in)
Suspension travel
rear	310 mm (12.2 in)
Fork offset	22 mm (0.87 in)
Shock absorber	WP XPLOR 5746
Brake system	Disc brakes, floating brake calipers
Brake discs - diameter
front	260 mm (10.24 in)
rear	220 mm (8.66 in)
Brake discs - wear limit
front	2.5 mm (0.098 in)
rear	3.5 mm (0.138 in)
Street tire pressure
front	1.5 bar (22 psi)
rear	1.5 bar (22 psi)
Offroad tire pressure
front	1.0 bar (15 psi)
rear	1.0 bar (15 psi)
Secondary ratio	14:50 (13:50)
Chain	5/8 x 1/4"
Rear sprockets available	45, 48, 49, 50, 51, 52
Steering head angle	63.5°
Wheelbase 1,482 ± 10 mm (58.35 ± 0.39 in)
Seat height unloaded 960 mm (37.8 in)
Ground clearance unloaded 370 mm (14.57 in)
Weight without fuel, approx. 100 kg (220 lb.)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
Maximum permissible overall weight 335 kg (739 lb.)

22.6 Electrical system

12-V battery YTX5L-BS Battery voltage: 12 V		Nominal capacity: 4 Ah Maintenance-free
Combination instrument battery CR	2430 Battery voltage: 3 V
Fuse	58011109110	10 A
Headlight	HS1/socket BX43t	12 V35/35 W
Turn signal	R10W / socket BA15s	12 V10 W
License plate lamp	LED

22.7 Tires

Front tire	Rear tire
90/90 - 21 M/C 54M M+S TTMetzeler MCE 6 DAYS EXTREME	140/80 - 18 M/C 70M M+S TTMetzeler MCE 6 DAYS EXTREME
The tires specified represent one of the possible series production tires. Additional information is available in the Service section under:http://www.ktm.com

22.8 Fork

Fork article number	14.18.8T.63
Fork	WP XPLOR 5348
Compression damping
Comfort	18 clicks
Standard	15 clicks
Sport	12 clicks
Rebound damping
Comfort	18 clicks
Standard	15 clicks
Sport	12 clicks
Spring length with preload spacer(s)	474 mm (18.66 in)
Spring rate
Weight of rider: 65 ... 75 kg (143 ... 165 lb.)	3.8 N/mm (21.7 lb/in)
Weight of rider: 75 ... 85 kg (165 ... 187 lb.)	4.0 N/mm (22.8 lb/in)
Weight of rider: 85 ... 95 kg (187 ... 209 lb.)	4.2 N/mm (24 lb/in)
Fork length	928 mm (36.54 in)
Fork oil per fork leg 625 ± 10 ml (21.13 ± 0.34 fl. oz.)	Fork oil (SAE 4) (48601166S1) (p. 144)

22.9 Shock absorber

Shock absorber article number 12.18.7T.63
Shock absorber WP XPLOR 5746
Low-speed compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
High-speed compression damping
Comfort 2.5 turns
Standard 2 turns
Sport 1 turn
Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Spring preload 10 mm (0.39 in)
Spring rate
Weight of rider: 65 ... 75 kg (143 ... 165 lb.)	57 ... 63 N/mm (325 ... 360 lb/in)
Weight of rider: 75 ... 85 kg (165 ... 187 lb.)	60 ... 66 N/mm (343 ... 377 lb/in)
Weight of rider: 85 ... 95 kg (187 ... 209 lb.)	63 ... 69 N/mm (360 ... 394 lb/in)
Spring length 225 mm (8.86 in)
Gas pressure 10 bar (145 psi)
Static sag	37 mm (1.46 in)
Riding sag	110 mm (4.33 in)
Fitted length 415 mm (16.34 in)
Shock absorber fluid ( p. 144)	SAE 2.5

22.10 Chassis tightening torques

Remaining screws, chassis	EJOT PTK60x25-Z 2 Nm (1.5 lbf ft)
Screw, seat fixing	EJOT EJOFORM PTK60x23/18	2.5 Nm (1.84 lbf ft)
Screw, emergency OFF switch	M4	0.4 Nm (0.3 lbf ft)
Screw, fixed grip	M4	5 Nm (3.7 lbf ft)Loctite®243TM
Spoke nipple, front wheel	M4.5	5 Nm (3.7 lbf ft)
Spoke nipple, rear wheel	M4.5	5 Nm (3.7 lbf ft)
Remaining nuts, chassis	M5	5 Nm (3.7 lbf ft)
Remaining screws, chassis	M5	5 Nm (3.7 lbf ft)
Screw, battery terminal	M5	2.5 Nm (1.84 lbf ft)
Screw, light switch	M5	1 Nm (0.7 lbf ft)
Screw, shock absorber adjusting ring	M5	5 Nm (3.7 lbf ft)
Screw, turn signal switch	M5	1 Nm (0.7 lbf ft)
Nut, cable on starter motor M6 4	Nm (3 lbf ft)
Remaining nuts, chassis M6 10 N	Nm (7.4 lbf ft)
Remaining screws, chassis M6 10	Nm (7.4 lbf ft)
Screw, ball joint of push rod on foot brake cylinder	M6 10 Nm (7.4 lbf ft)	Loctite®243TM
Screw, chain sliding guard M6 6	Nm (4.4 lbf ft)	Loctite®243TM
Screw, front brake disc M6 14 N	Nm (10.3 lbf ft)	Loctite®243TM
Screw, manifold on silent block M6 6 Nm (4.4 lbf ft)
Screw, rear brake disc M6 14 Nm	(10.3 lbf ft)	Loctite®243TM
Screw, silent block on frame M6	6 Nm (4.4 lbf ft)
Screw, throttle grip M6 5 Nm (3.7 lbf ft)
Nut, foot brake lever M8 15 Nm	(11.1 lbf ft)
Nut, foot brake lever stop M8 20	Nm (14.8 lbf ft)
Nut, rear sprocket screw	M8 35 Nm (25.8 lbf ft)	Loctite®2701TM
Nut, rim lock	M8 12 Nm (8.9 lbf ft)
Remaining nuts, chassis M8 25 Nm (18.4 lbf ft)
Remaining screws, chassis M8 25	Nm (18.4 lbf ft)
Screw, bottom triple clamp	M8 15 Nm (11.1 lbf ft)
Screw, chain sliding piece	M8 15 Nm (11.1 lbf ft)
Screw, engine brace	M8x15	25 Nm (18.4 lbf ft)Loctite®2701TM
Screw, engine brace	M8x20	25 Nm (18.4 lbf ft)Loctite®243TM
Screw, fork stub	M8 15 Nm (11.1 lbf ft)
Screw, front brake caliper	M8 25 Nm (18.4 lbf ft)	Loctite®243TM
Screw, handlebar clamp	M8 20 Nm (14.8 lbf ft)
Screw, side stand attachment	M8 33 Nm (24.3 lbf ft)	Loctite®2701TM
Screw, subframe bottom M8 30 Nm (22.1 lbf ft)		Loctite®2701TM
Screw, subframe top	M8 35 Nm (25.8 lbf ft)	Loctite®2701TM
Screw, top steering stem	M8 20 Nm (14.8 lbf ft)
Screw, top triple clamp	M8 20 Nm (14.8 lbf ft)
Engine bracket screw	M10	60 Nm (44.3 lbf ft)
Remaining nuts, chassis M10	45 Nm (33.2 lbf ft)
Remaining screws, chassis M10	45 Nm (33.2 lbf ft)
Screw, handlebar support	M10	40 Nm (29.5 lbf ft)Loctite®243TM
Screw, bottom shock absorber	M12	80 Nm (59 lbf ft)Loctite®2701TM
Screw, top shock absorber	M12	80 Nm (59 lbf ft)Loctite®2701TM
Nut, fork pivot	M16x1.5	100 Nm (73.8 lbf ft)

22 TECHNICAL DATA

Nut, rear wheel spindle M20x1.5	80 Nm (59 lbf ft)
Screw, front wheel spindle M20x1.5	35 Nm (25.8 lbf ft)
Screw, top steering head M20x1.5	12 Nm (8.9 lbf ft)
Screw-in fitting, cooling system M	24x1.5 15 Nm (11.1 lbf ft)	Loctite®243TM

Brake fluid DOT 4 / DOT 5.1

Standard/classification

- DOT

Guideline

- Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties.

Recommended supplier

Castrol

- REACT PERFORMANCE DOT 4

MOTOREX®

- Brake Fluid DOT 5.1

Coolant

Guideline

• Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors. Low grade and unsuitable antifreeze causes corrosion, deposits and frothing.
• Do not use pure water as only coolant is able to meet the requirements needed in terms of corrosion protection and lubrication properties.
• Only use coolant that complies with the requirements stated (see specifications on the container) and that has the relevant properties.

Antifreeze protection to at least -25 °C (-13 °F)

The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant needs to be diluted.

The use of premixed coolant is recommended.

Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility) with other coolants.

Recommended supplier

MOTOREX®

- COOLANT M3.0

Engine oil (15W/50)

Standard/classification

- JASO T903 MA2 (p. 147)

- SAE (p. 147) (15W/50)

Guideline

- Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties.

Recommended supplier

MOTOREX®

- Top Speed 4T

Engine oil, 2-stroke

Standard/classification

- JASO FD (p. 147)

Guideline

- Only use high grade 2-stroke engine oil of a reputable brand.

Fully synthetic

Recommended supplier

MOTOREX®

- Cross Power 2T

Fork oil (SAE 4) (48601166S1)

Standard/classification

- SAE (p. 147) (SAE 4)

Guideline

- Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

Shock absorber fluid (SAE 2.5) (50180751S1)

Standard/classification

- SAE (p. 147) (SAE 2.5)

Guideline

- Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

Super unleaded, type C (ROZ 95/RON 95/PON 91 mixed with 2-stroke engine oil, 1:60)

Standard/classification

- ANP (Agência Nacional do Petróleo) #57 (ROZ 95/RON 95/PON 91 mixed with 2-stroke engine oil) - JASO FD (p. 147) (1:60)

Mixture ratio

1:60 Engine oil, 2-stroke (p. 143) Super unleaded, type C (ROZ 95/RON 95/PON 91) (p. 144)

Recommended supplier

MOTOREX®

- Cross Power 2T

Super unleaded, type C (ROZ 95/RON 95/PON 91)

Standard/classification

- Only use super unleaded fuel that matches or is equivalent to the following specifications. - Super unleaded fuel with an ethanol content of 19 to 27% is permissible.

Info

Do not use fuel made of methanol (e. g. M15, M85, M100).

Do not use fuel with less than 19 % ethanol (e. g. E10).

Do not use fuel with more than 27 % ethanol (e. g. E30, E85, E100).

Air filter cleaner

Recommended supplier

MOTOREX®

- Racing Bio Dirt Remover

Chain cleaner

Recommended supplier MOTOREX®

- Chain Clean

Fuel additive

Recommended supplier MOTOREX®

- Fuel Stabilizer

High viscosity grease

Recommended supplier SKF®

- LGHB 2

Long-life grease

Recommended supplier MOTOREX®

- Bike Grease 2000

Motorcycle cleaner

Recommended supplier MOTOREX®

- Moto Clean

Off-road chain spray

Recommended supplier MOTOREX®

- Chainlube Offroad

Oil for foam air filter

Recommended supplier MOTOREX®

- Racing Bio Liquid Power

Preserving materials for paints, metal and rubber

Recommended supplier MOTOREX®

- Moto Protect

24 AUXILIARY SUBSTANCES

Special cleaner for glossy and matte paint finishes, metal and plastic surfaces

Recommended supplier

MOTOREX®

- Quick Cleaner

Universal oil spray

Recommended supplier

MOTOREX®

- Joker 440 Synthetic

JASO T903 MA2

Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard.

Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle specification.

Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

In most motorcycle engines, the transmission and clutch are lubricated with the same oil.

The JASO T903 MA2 standard meets these special requirements.

SAE

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

JASO FD

JASO FD is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first-rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions.

26 LIST OF ABBREVIATIONS

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

27.1 Yellow and orange symbols

Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols.

	Malfunction indicator lamp – inoperative
	Fuel level warning lamp – inoperative

27.2 Green and blue symbols

Green and blue symbols reflect information.

	The high beam indicator lamp lights up blue – The high beam is switched on.
	Turn signal indicator lamp flashes green – The turn signal is switched on.

1

12-V battery

charging

installing

removing

A

Accessories

Air filter

cleaning

installing

removing

Air filter box

cleaning

Air filter box cover

installing

preparing for securing

removing

Antifreeze

checking

Auxiliary substances

B

Basic chassis setting

rider's weight, checking with

Brake discs

checking

Brake fluid

of front brake, adding

of rear brake, adding

Brake fluid level

of front brake, checking

rear brake, checking

Brake linings

front brake, checking

of front brake, changing

of the rear brake, changing

rear brake, checking

C

Capacity

coolant

fuel

Gear oil

Carburetor

float chamber, emptying

Idle speed

idle speed, adjusting

Carburetor tuning

Chain

checking 7€

cleaning 74

ChainOguide

checking 76

Chain102 tension

adjusting 75

checking 74

Choke

Cleaning, care 128-129

Clutch 68

fluid level, checking/correcting 81

fluid, changing 82

Clutch6Fever

basic position, adjusting 81

Combination instrument

692-V battery, changing ..... 109

adjusting 23

clock, setting 24

kilometers or miles, setting 22

overview 22

Compression damping

fork, adjusting 53

Coolant

47draining 112

refilling 113

Coolant ^84 level

checking 111-112

86 Cooling system

Customer service 10

D

85

Difficult operating conditions 35

dry sand 36

_87 low temperature ..... 39

muddy surfaces 38

snow

93 wet sand 3

93 wet surfaces 38

Difficult riding conditions

high temperatures 39

sl08 speed 39

44, 138

1. 138

Emergency OFF switch 16

Engine

running in 35

Engine characteristic

auxiliary spring 122

auxiliary spring, adjusting ..... 122

Engine number 13

Engine sprocket checking free travel, checking 84 76 Handlebar position 54

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

F Headlight Figures range, adjusting 109

Filling up Headlight bulb fuel changing 107

Foot brake lever Headlight mask with headlight basic position, adjusting 90 installing 106 free travel, checking 50 removing 106

Fork Headlight setting article number checking 108

basic setting, checking .... High-speed compression damping Fork legs shock absorber, adjusting .... 48

bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 dust boots, cleaning . . . . . . . . . . . . . . . . . . . . . . . I. 57 installing 2.10 mm (300 mm) or 100 mm (300 mm) or 100 mm (300 mm) or 50 mm (59).

removing Ignition timing map Fork protector changing 120 installing plug-in connector 120

removing Implied warranty 10

Frame intended use ....../7 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K. 79

Front fender Key number 13 installing L . 64 removing Light switch 16

Front wheel Link fork installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 removing . . . . . . . . . . . . . . . . . . . . . . . . Lower triple clamp

Fuel tank installing 60 installing 72 removing 59 removing 71

Fuel tank filler cap closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 opening . . . . . . . . . . . . . . . . . . . . . . . . . M 18 M 17

Fuel tap.... Main fuse.... 18 Fuel, oils, etc. .... changing.... 105

Fuse Main silencer main fuse, changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 glass fiber yarn filling, changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 removing. 70

Gear oil Manufacturer warranty .... 10 adding .... Misuse ^126 .... 7 changing .... 125.

Gear oil level checking cleaning 128 from lift stand, removing 56 raising with lift stand 56

Hand brake lever 0.15 free travel, adjusting .Overview of indicator lamps 17

Owner's Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering head bearing
P lubricating 64
Preparing for use Steering head bearing play adjusting
advice on preparing for first use .... 34 adjusting .... 62 after storage .... 131 checking .... 62
checks and maintenance measures when Preparing for use .... 130 Storage .... 15 Switch-off button .... 15
Protective clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T . . 9
R Technical data
Rear sprocket capacities .... 138 checking . . . carburetor .... 137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear wheel chassis tightening torques 140 installing 98 electrical system 139 removing 97 engine 134
Rebound damping engine tightening torques 134 fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 shock absorber, adjusting 49 shock absorber 140
Riding sag tires ..... 13 adjusting ..... Throttle cable play
Rubber grip adjusting 115 checking checking 115
S Throttle cable routing Safe operation checking 79
Seat Throttle grip
mounting Tire condition
removing checking 100
Service Tire pressure Service schedule 45 checking 100
Shift lever 19 Transporting 43
basic position, adjusting 121 Troubleshooting 132-133
basic position, checking 1Turn signal bulb
Shock absorber changing 107 article number Turn signal switch 16
compression damping, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 installing. U 65
riding sag, checking .... 50 spring preload, adjusting .... V51
static sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Side stand 20 View of vehicle
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : front Qeft
Spoke tension rear right 1 checking w. 101
Start button 17 Winter operation Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . checks and maintenance steps 129
Steering Work rules locking 20 unlocking 21

Barcode image containing encoded digital information

3214008en

01/2019

Side profile of a white K-DA motor with visible tire, chain, and gear assembly (no text or symbols)

Orange background with black KTM logo (no text or symbols)

KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria http://www.ktm.com

Photo: Mitterbauer/KISKA/KTM