Instruction/ maintenance manual of the product 1190 RC8 AUS/UK KTM
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OWNER 'S MANU AL 2008 1190 RC8 EU 1190 RC8 AU S/UK 1190 RC8 FR 1190 RC8 JP ART. NO. 3211250e n.
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DEAR KTM CUS TOMER 1 DEAR KTM CUSTOMER Congratulations on yo ur decision to purchase a KT M motorcycle. You are no w the owner of a state-of-the- art sports motorcycle tha t will give you enormous ple asure if you service and mai ntain it accordingly.
DEAR KTM CUS TOMER 2 © 2008 by KTM-Sportm otorcycle AG, Mattighof en Austria All rights reserved Reproduction, even in p art, is permitted only with the e xpress written permiss ion of the copyright owner.
CONTENTS 3 CONTENTS MEANS OF REPRESEN TATION ............................ ................... 7 IMPORTANT NOTES ............................ ............................... .... 8 VIEW OF VEHICLE ............................ ..........................
CONTENTS 4 Setting number of laps SE T NUM LAPS ......................... ..... 66 Setting fuel reserve dis play TRIPF RESET ........................... 67 Setting kilometers/m iles SET KM/MILES............................. 68 Setting temperature u nit SET °C/°F .
CONTENTS 5 Adjusting shift lever ................................. ....................... 116 Adjusting the footbrak e pedal stub ........... ........................ 120 Adjusting the footbrak e pedal ........................... ............... 121 checking for chain dirt .
CONTENTS 6 Fitting oil filter x ......... .............................. ................... 190 Filling up with engine oil x ............................. ............... 190 Topping up engine oil ....................................... .....
MEANS OF RE PRESENTA TION 7 1 MEANS OF REPRESENTAT ION Symbols used The following explain s the meaning of specific sy mbols. Identifies an expecte d reaction (e.g. of an operatio n or a function). Identifies an unexpec ted reaction (e.g. of an opera tion or a function).
IMPORTA NT NOTES 8 2 IMPORTANT NOTES Use definition KTM sport motorcycle s are designed and constr ucted to meet the normal de mands of regular road and ra ce track operation, but not fo r use on dirt roads. Info The motorcycle is auth orized for public road traffic i n the homologous versio n only.
IMPORTA NT NOTES 9 You will find the current KTM PowerParts for your v ehicle on the KTM website . International KTM W ebsite: http://www.ktm .com Work rules During assembly, non -reusable parts (e.g. self -locking screws and nuts , seals and seal rings, O-ring s, pins, lock washers) mu st be replaced by new parts.
IMPORTA NT NOTES 10 notes/warnings Be sure to pay attention to th e notes and warnings given h ere. Info Various notes and warn ing stickers are attached to t he vehicle. Do not remove a ny notes and warning stick ers. If these are removed, you or other persons may n ot recognize potential da nger and therefore be liab le to injury.
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VIEW OF VEHICL E 12 3 VIEW OF VEHICLE 3.1 View of vehicle, fron t left side 700243-10.
VIEW OF VEHICL E 13 1 Clutch lever 2 Light switch, headlig ht flasher switch, indic ator switch, horn button 3 Filler cap 4 Seat 5 Seat lock 6 Oil dipstick 7 Side stand 8 Shift lever 9 Passenger footr.
VIEW OF VEHICL E 14 3.2 View of vehicle, rear r ight side 700242-10.
VIEW OF VEHICL E 15 1 Passenger seat 2 Supporting strap 3 Rear mirror 4 Combination instrum ent 5 Emergency OFF switc h, electric starter button 6 Hand brake lever 7 Chassis number, type l abel 8 Rear.
LOCATION O F SERIAL NUM BERS 16 4 LOCATION OF SERIAL NU MBERS 4.1 Chassis number/ty pe label 700231-01 The chassis number i s stamped on the frame beh ind the steering head on the rig ht. The type label is on the fra me above the chassis num ber.
LOCATION O F SERIAL NUM BERS 17 4.3 Engine number 700223-01 The engine number is s tamped on the right side of the e ngine. 4.4 Fork part number 700224-01 The fork part number is s tamped on the inner side of th e fork stub.
LOCATION O F SERIAL NUM BERS 18 4.5 Shock absorber par t number 700225-01 The shock absorber pa rt number is stamped on th e upper part of the shock abso rber above the adjusting rin g towards the rear. 4.6 Steering damper pa rt number 700226-01 The steering damper pa rt number is stamped on t he top of the steering dampe r.
OPERATIN G ELEMENTS 19 5 OPERATING ELEMENTS 5.1 Clutch lever 700227-01 The clutch lever is fitte d on the left side of the handleba r. The clutch is hydraulic a nd self-adjusting. 5.2 Hand brake lever 700228-01 The handbrake lever i s fitted on the right side of the han dlebar.
OPERATIN G ELEMENTS 20 5.3 Light switch 700230-13 The light switch is fitted o n the left side of the handleba r. Possible states Low beam on – Light switch i s turned downwards. In this p osition, the low beam and tail light are swit ched on.
OPERATIN G ELEMENTS 21 5.5 Flasher switch 700230-12 The flasher switch is fit ted on the left side of the handle bar. Possible states Flasher light off Flasher light, left, on – Flasher switch presse d to the right. The flasher switch returns automa tically to the central positi on after use.
OPERATIN G ELEMENTS 22 5.7 Ignition/steering lo ck 700234-01 The ignition/steerin g lock is located in front of the u pper triple clamp. Possible states Ignition off – In this posit ion, the ignition circuit is int errupted, a running engine stops, and a non- running engine will not star t.
OPERATIN G ELEMENTS 23 5.9 Electric starter button 700229-12 The electric starter butt on is fitted on the right side of th e handlebar. Possible states • Electric starter button in neutral position • Electric starter button pressed – In this positi on, the electric starter is ope rated.
OPERATIN G ELEMENTS 24 5.10 Combination instru ment - overview 400430-10 1 display ( S. 27) 2 Function buttons 3 Indicator lamps ( S. 29) 4 info display ( S.
OPERATIN G ELEMENTS 25 5.11 Combination instru ment - function button s on handlebar 600642-10 The Mode button is fitted on the handlebar, fro nt left.
OPERATIN G ELEMENTS 26 5.12 Combination instru ment - activation and tes t 400429-10 Activation The combination inst rument is activated when th e ignition is switched on. Test The segments of the tach ometer light up in and switch o ff in sequence. The speed display cou nts from 0 to 300 and back.
OPERATIN G ELEMENTS 27 5.13 display 400430-12 The tachometer dis plays the engine speed in re volutions per minute (RP M). The red marking mark s the over-rev (excessiv e speed) range of the engine . The speed is displaye d in kilometers per hour k m/h or in miles per hour Mp h .
OPERATIN G ELEMENTS 28 5.14 info display 400430-13 The info display has two m enus. Menu 1 is ROAD mode (st andard) for riding on public ro ads. Menu 2 is RACE mode for rid ing on race courses. It allow s riders to time laps themse lves.
OPERATIN G ELEMENTS 29 5.15 Indicator lamps 400430-14 Possible states The flasher indicator la mp flashes green in same rh ythm as the flasher. – The flasher is switche d on. The oil indicator lamp lig hts up red – The oil pressure i s too low.
OPERATIN G ELEMENTS 30 5.16 Notes/warnings on t he combination instru ment 400476-01 LOW FUEL appears on th e info display if the minimum range falls below the sp ecified value. Distance 25 km (15.5 mi) 400471-01 LOW BATTERY appear s on the info display if the batte ry voltage falls below the sp ecified value.
OPERATIN G ELEMENTS 31 400472-01 SERVICE IN xxx KM(M PH) appears on the info disp lay if the distance to the next s ervice falls below the specified va lue. Distance 500 km (310 .7 mi) 400474-01 HIGH TEMP appears on t he info display if the coolant te mperature rises above t he specified value.
OPERATIN G ELEMENTS 32 400470-01 REAR SENSOR appear s on the info display if the coola nt temperature sensor of th e rear cyclinder is defective . 400468-01 SENSOR ERROR appea rs on the info d.
OPERATIN G ELEMENTS 33 5.17 ODO menu 400438-01 Condition • The ignition is on. • ROAD mode – Press the MODE button b riefly and repeatedly un til ODO appears at the top left of th e info display. ODO shows the total distan ce covered. TripDist shows the dist ance covered since the las t reset.
OPERATIN G ELEMENTS 34 5.18 FUELDISTANCE m enu 400441-01 Condition • The ignition is on. • ROAD mode – Press the MODE button b riefly and repeatedly un til FUELDISTANCE appe ars at the top of the info display. TripFuel shows the dis tance covered since the fu el reserve level was reach ed.
OPERATIN G ELEMENTS 35 5.19 FUELRANGE menu 400477-01 Condition • The ignition is on. • ROAD mode – Press the MODE button b riefly and repeatedly un til FUELRANGE appears at th e top of the info display. TripFuel shows the dis tance covered since the fu el reserve level was reach ed.
OPERATIN G ELEMENTS 36 5.20 DISTANCE TO Next Service menu 400443-01 Condition • The ignition is on. • The motorcycle is stan ding. • ROAD mode – Press the MODE button b riefly and repeatedly un til DISTANCE TO Next Ser vice appears in the info display.
OPERATIN G ELEMENTS 37 5.21 LAPSTOGO menu 400444-01 Condition • The ignition is on. • RACE mode – Press the MODE button b riefly and repeatedly un til LAPSTOGO appears at the t op left of the info display. LAPSTOGO shows the num ber of remaining laps.
OPERATIN G ELEMENTS 38 5.22 TOPSPEED menu 400445-01 Condition • The ignition is on. • RACE mode – Press the MODE button b riefly and repeatedly un til TOPSPEED appears at th e top left of the info display. If an R appears after TOPSPE ED , the stopwatch is runni ng in the background.
OPERATIN G ELEMENTS 39 5.23 LAP/BESTLAP/L astLap menu 400446-01 Condition • The ignition is on. • The motorcycle is stan ding. • RACE mode – Press the MODE button b riefly and repeatedly un til LAP/BESTLAP/LastL ap appears in the info display.
OPERATIN G ELEMENTS 40 5.24 LAP/BESTLAP/T opSpeed menu 400447-01 Condition • The ignition is on. • The motorcycle is stan ding. • RACE mode – Press the MODE button b riefly and repeatedly un til LAP/BESTLAP/TopS peed appears in the info display.
OPERATIN G ELEMENTS 41 5.25 Total distance menu i n Race mode RACE ODO 400448-01 Condition • The ignition is on. • The motorcycle is stan ding. • RACE mode – Press the MODE button b riefly and repeatedly un til RACEODO appears at the to p of the info display.
OPERATIN G ELEMENTS 42 5.26 SET ‑ UP menu 400449-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button and the button for 3 - 5 seco nds. On the CHANGE MODE m enu, you can select betwe en ROAD and RACE mo de.
OPERATIN G ELEMENTS 43 5.27 CHANGE MODE m enu 400475-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button and the button for 3 - 5 seco nds. – Press the button or the button briefly a nd repeatedly until the symbol is o n CHANGE MODE in the info d isplay.
OPERATIN G ELEMENTS 44 5.28 SET CLOCK menu 400455-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button and the button for 3 - 5 seco nds. – Press the button once until the symbol is on SET CLOCK in the info disp lay.
OPERATIN G ELEMENTS 45 5.29 SETTINGS menu 400456-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button and the button for 3 - 5 seco nds. – Press the button twice until the symbol is on SETTINGS in the info dis play.
OPERATIN G ELEMENTS 46 5.30 SHIFT RPMS men u 400460-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button and the button for 3 - 5 seco nds. – Press the button twice until the symbol is on SETTINGS in the info dis play.
OPERATIN G ELEMENTS 47 5.31 LAP menu, LAP BL ANK T button 400461-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button and the button for 3 - 5 seco nds. – Press the button twice until the symbol is on SETTINGS in the info dis play.
OPERATIN G ELEMENTS 48 5.32 SET NUM LAPS me nu 400462-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button and the button for 3 - 5 seco nds. – Press the button twice until the symbol is on SETTINGS in the info dis play.
OPERATIN G ELEMENTS 49 5.33 TRIP F RESET men u 400463-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button and the button for 3 - 5 seco nds. – Press the button twice until the symbol is on SETTINGS in the info dis play.
OPERATIN G ELEMENTS 50 5.34 UNITS menu 400458-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button and the button for 3 - 5 seco nds. – Press the button three times un til the symbol is on UNITS in the info dis play.
OPERATIN G ELEMENTS 51 5.35 SET KM/MILES men u 400464-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button and the button for 3 - 5 seco nds. – Press the button three times un til the symbol is on UNITS in the info dis play.
OPERATIN G ELEMENTS 52 5.36 SET °C/°F menu 400465-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button and the button for 3 - 5 seco nds. – Press the button three times un til the symbol is on UNITS in the info dis play.
OPERATIN G ELEMENTS 53 5.37 OPTIONS menu 400459-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button and the button for 3 - 5 seco nds. – Press the button four times un til the symbol is on OPTIONS in the inf o display.
OPERATIN G ELEMENTS 54 5.38 TPMS menu 400478-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button and the button for 3 - 5 seco nds. – Press the button four times un til the symbol is on OPTIONS in the inf o display.
OPERATIN G ELEMENTS 55 5.39 OPTION OUTERT EMP menu 400466-01 Condition • The ignition is on. • The motorcycle is stan ding. – Press the button and the button for 3 - 5 seco nds. – Press the button four times un til the symbol is on OPTIONS in the inf o display.
OPERATIN G ELEMENTS 56 Table of functions Display Press the button . Press the button . Press the button and the button for 3 - 5 seconds.
OPERATIN G ELEMENTS 57 Table of functions Display Press the button . Press the button . Press the button and the button for 3 - 5 seconds.
OPERATIN G ELEMENTS 58 Table of functions Display Press the button . Press the button . Press the button and the button for 3 - 5 seconds.
OPERATIN G ELEMENTS 59 Table of conditions a nd activability Display • The igni- tion is on. • ROAD mode • The igni- tion is on. • The motor- cycle is standing. • ROAD mode • The igni- tion is on. • RACE mode • The igni- tion is on.
OPERATIN G ELEMENTS 60 Table of conditions a nd activability Display • The igni- tion is on. • ROAD mode • The igni- tion is on. • The motor- cycle is standing. • ROAD mode • The igni- tion is on. • RACE mode • The igni- tion is on.
OPERATIN G ELEMENTS 61 400446-01 – Press the MODE button b riefly and repeatedly un til LAP/BESTLAP/LastL ap appears in the info display. LAP01 appears on the left of th e info display. – Press the button . The next lap is displayed . – Press the button .
OPERATIN G ELEMENTS 62 5.42 Setting ROAD or RA CE mode Condition The ignition is on. The motorcycle is stan ding. 400475-01 – Press the button and the button for 3 - 5 seco nds. – Press the button or the button briefly a nd repeatedly until the symbol is o n CHANGE MODE in the info d isplay.
OPERATIN G ELEMENTS 63 400455-01 – Press the button and the button for 3 - 5 seco nds. – Press the button once until the symbol is on SET CLOCK in the info disp lay. – Press the MODE button b riefly. The hour is shown. – Set the hour with the button or the bu tton .
OPERATIN G ELEMENTS 64 – Press the MODE button b riefly. RPM1 and RPM2 appe ar on the info display. The engine speed after RPM1 flashes. Info The engine speed can be s et at intervals of 50. RPM1 is the engine speed a bove which the shift warnin g light starts to flash.
OPERATIN G ELEMENTS 65 – Press the MODE button b riefly. 5.45 Setting the blank time o f the LAP button LAP BLANK T Condition The ignition is on. The motorcycle is stan ding. 400461-01 – Press the button and the button for 3 - 5 seco nds.
OPERATIN G ELEMENTS 66 – Press the button briefly and rep eatedly until the symbol is on EXIT SETUP in the info display. – Press the MODE button b riefly. 5.46 Setting number of laps S ET NUM LAPS Condition The ignition is on.
OPERATIN G ELEMENTS 67 – Press the MODE button b riefly. 5.47 Setting fuel reserve di splay TRIPF RES ET Condition The ignition is on. The motorcycle is stan ding. 400463-01 – Press the button and the button for 3 - 5 seco nds. – Press the button twice until the symbol is on SETTINGS in the info dis play.
OPERATIN G ELEMENTS 68 5.48 Setting kilometers/ miles SET KM/MIL ES Info Making a country-spe cific setting. Condition The ignition is on. The motorcycle is stan ding. 400464-01 – Press the button and the button for 3 - 5 seco nds. – Press the button three times un til the symbol is on UNITS in the info dis play.
OPERATIN G ELEMENTS 69 5.49 Setting temperatu re unit SET °C/°F Condition The ignition is on. The motorcycle is stan ding. 400465-01 – Press the button and the button for 3 - 5 seco nds. – Press the button three times un til the symbol is on UNITS in the info dis play.
OPERATIN G ELEMENTS 70 400466-01 – Press the button and the button for 3 - 5 seco nds. – Press the button four times un til the symbol is on OPTIONS in the inf o display. – Press the button once until the symbol is on OPTIONS OUTTEMP i n the info dis- play.
OPERATIN G ELEMENTS 71 5.51 Opening the filler cap 700235-01 – Lift the cover of the filler c ap and insert the ignition key i n the lock. – Turn the ignition key cloc kwise until the filler cap ope ns.
OPERATIN G ELEMENTS 72 5.52 Closing the filler cap 700236-01 – Close the filler cap. Push d own the filler cap slightly unt il the lock closes. – Remove the ignition ke y and close the cover. 5.53 Supporting strap 700244-01 The supporting strap is provided for the passen ger to hold on to.
OPERATIN G ELEMENTS 73 5.54 Seat lock 700245-01 The seat lock is behind th e seat. It can be locked with the igni tion key. 5.55 Tool set 700310-01 The tool set is in the storag e compartment under the s eat.
OPERATIN G ELEMENTS 74 5.56 Helmet lock 700337-01 The steel cable in the tool se t can be used to lock a helmet to th e vehicle to prevent it from being stolen. Warning Danger of accident s Impairment of handlin g characteristics and ve hicle operation by a fitted helmet lock or hel met.
OPERATIN G ELEMENTS 75 5.58 Shift lever 700239-01 The shift lever is mount ed on the left of the engine. 700238-01 The gear positions can b e seen in the picture.
OPERATIN G ELEMENTS 76 5.59 Foot brake pedal 700237-01 The footbrake pedal i s in front of the right footrest. The footbrake pedal op erates the rear brake. 5.60 Side stand 700258-01 The side stand is coup led with the safety start syste m; see the riding instructi ons.
TIPS ON PUTT ING INTO OPER ATION 77 6 TIPS ON PUTTING INTO OPE RATION 6.1 advice on first use Danger Danger of accident s Danger from insuffici ent traffic competenc e. – Do not use the vehicle if you a re not fit to deal with traffic or if you ha ve consumed alcohol an d/or medicaments or dru gs.
TIPS ON PUTT ING INTO OPER ATION 78 Info When using your vehic le, remember that others m ay feel disturbed by exces sive noise. – Make sure that the pre-de livery inspection work ha s been carried out exclus ively by an authorized KTM -RC8 workshop.
TIPS ON PUTT ING INTO OPER ATION 79 – Avoid full-throttle ope ration! 6.3 Loading the vehicle Warning Danger of accident s Unstable riding behav ior.
TIPS ON PUTT ING INTO OPER ATION 80 Warning Danger of accident s Unstable handling ch aracteristics due to slipp ed baggage. – Check the way your bagg age is fixed regularly.
RIDING INST RUCTIONS 81 7 RIDING INSTRUCTIONS 7.1 checks to be made bef ore putting into operatio n Info During operation, the m otorcycle must be in a techn ically perfect condition . In the interest of riding safe ty, you should get into the hab it of making a general chec k of the motorcycle before ev ery journey.
RIDING INST RUCTIONS 82 7.2 Starting Danger Danger of poisoning Exhaust gases are pois onous and can result in unc onsciousness and/or d eath. – When running the engin e, always make sure there is s ufficient ventilation, a nd do not start or run the engine in a c losed space.
RIDING INST RUCTIONS 83 700248-01 – Press the emergency O FF switch into the position . – Switch on the ignition by tu rning the black ignition key t o the position . When you switch on the ign ition, you hear the fuel pump w orking for about 2 sec- onds.
RIDING INST RUCTIONS 84 7.4 Shifting, riding Warning Danger of accident s An abrupt load alteration s can cause the vehicle to ge t out of control. – Avoid abrupt load altera tions and sudden brakin g actions, and adapt your sp eed to the road conditions .
RIDING INST RUCTIONS 85 Warning Danger of accident s Reduced road grip with co ld tires. – On every journey, take th e first miles carefully at mod erate speed until the tires re ach operating temperat ure and optimal road grip is ensured. Warning Danger of accident s Reduced road grip with ne w tires.
RIDING INST RUCTIONS 86 Note Engine damage En gine overheating. – If the coolant temperatu re warning lamp lights up, st op the vehicle and switch of f the engine. Let the engine co ol down, and then check the coolant leve l in the radiator and top up if neces sary.
RIDING INST RUCTIONS 87 – If the EFI warning lamp ( MIL ) starts to light up during th e journey, stop immedia tely. If you shift to neutral, the E FI warning lamp ( MI L ) begins to flash. Info From the flash rhythm, yo u can deduce a two-digit num ber, the so-called flash code.
RIDING INST RUCTIONS 88 Warning Danger of accident s Delayed brake action on s alted roads. – Salt can be deposited on th e brake discs. To achieve th e normal braking effect, th e brake discs must first be cle aned by brak- ing. – When braking, first thro ttle back and then apply the fro nt and rear brakes at the sam e time.
RIDING INST RUCTIONS 89 – Do not place the vehicle wh ere there are flammable or e xplosive substances . Note Material damage Damage and destructio n of components by exces sive load. – The side stand is design ed for the weight of the motorcy cle only.
RIDING INST RUCTIONS 90 Warning Danger of poisoning Fuel is poisonous and a he alth hazard. – Avoid contact betwe en fuel and skin, eyes an d clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse im mediately with water and contact a do ctor.
GREASING A ND SERVICE T ABLE 91 8 GREASING AND SERVICE TA BLE 8.1 Important service ta sks to be carried out by an au thorized KTM-RC8 w orkshop. K10N K75A K150A J1A J2A Engine Change the eng ine oil and filter, clean the oil sc reen. x ( S. 185) ••••• Check the valve cleara nce and adjust if necessar y.
GREASING A ND SERVICE T ABLE 92 K10N K75A K150A J1A J2A Attachments Check bowden c ables for damage, smoo th operation, kink-free ro uting and adjustment. x ••••• Check the fluid level of the h ydraulic clutch. ( S. 175) • • • • Check the air filter and cha nge if necessary.
GREASING A ND SERVICE T ABLE 93 K10N K75A K150A J1A J2A Chassis Check the stee ring head bearing and adju st if necessary. x ••• Check the swingarm be aring. x ••• Check deflector. x • • Check the eccentric sh aft adjustment.
GREASING A ND SERVICE T ABLE 94 8.2 Important service ta sks to be carried out by an au thorized KTM-RC8 w orkshop. (as additio nal job) K150A K300A J1A J2A Completely service fo rk. x • Completely service s hock absorber. x • Clean and grease the ste ering head bearing and sea ling elements.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 95 9 MAINTENANCE WORK ON C HASSIS AND ENGINE 9.1 Jacking up motorcyc le front Note Danger of damage D anger of damage by the veh icle running away or falling o ver. – Always place the vehic le on a firm and even surface.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 96 9.3 Jacking up motorcyc le rear Note Danger of damage D anger of damage by the veh icle running away or falling o ver. – Always place the vehic le on a firm and even surface. 700251-01 – Insert the work stand ada pter in the rear of the work stand.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 97 9.5 Fork/shock absorb er 700252-01 The fork and the shock abs orber offer many options o f adapting the chassis to yo ur riding style and the payload. Info To help you adapt the vehi cle, we have summarized o ur findings in Table .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 98 700253-01 – Turn adjusting screws clockwise until they sto p. Info The adjusting screws a re located at the bottom end of th e fork legs. Make the same adjustm ent on both fork legs. – Turn back counterclo ckwise the number of click s corresponding to the fork t ype.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 99 700347-01 – Turn adjusting screws clockwise until they sto p. Info The adjusting screws a re located at the top end of the fork l egs. Make the same adjustm ent on both fork legs. – Turn back counterclo ckwise the number of click s corresponding to the fork t ype.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 100 700348-01 – Turn the adjusting spin dles clockwise until th ey stop. Info The adjusting spindle s are located at the top end of the fo rk legs. Make the same adjustm ent on both fork legs. – Turn back counterclo ckwise the number of turns c orresponding to the fork ty pe.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 101 700259-01 – Remove bleeder scre ws briefly. Any excess pressure e scapes from the interior of th e fork.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 102 Info The low-speed setting c an be seen during the slow to n ormal compression of th e shock absorber. 700255-01 – Turn the adjusting scre w clockwise with a screw driver up to the last percepti ble click.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 103 9.12 Adjusting high-spe ed compression dam ping of the shock absorb er Danger Danger of accident s The shock absorber is un der high pressure. – The shock absorber is fil led with highly compress ed nitrogen, so never dism antle the shock absorbe r or carry out any mainte- nance on it yourself.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 104 9.13 Adjusting rebound d amping of the shock abs orber Danger Danger of accident s The shock absorber is un der high pressure. – The shock absorber is fil led with highly compress ed nitrogen, so never dism antle the shock absorbe r or carry out any mainte- nance on it yourself.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 105 Info The spring preload defi nes the initial situation of the s pring process on the shoc k absorber. An optimally adjusted s pring preload is adapted to t he rider's weight and ensu res a compromise betwee n easy handling and stab il- ity.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 106 – Turn the adjusting ring cl ockwise and tension it to the s pecified value. Guideline Spring preload Comfort 6 mm (0.24 in) Standard 6 mm (0.24 in) Sport 8 mm (0.31 in) full payload 8 mm (0.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 107 9.15 Steering damper 700339-01 The steering damper su ppresses shocks to the st eering arising from acce leration on uneven ground at high speed or wh en the load is temporarily tak en from the front wheel.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 108 – Adjust the steering dam per according to your ridin g style and the road conditio ns by turning the adjust screw clockwise towards " + ".
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 109 9.17 Vehicle level 700333-01 Warning Danger of accident s Modifications to the cha ssis can seriously alter th e vehicle's handling characteri stics. – Following modificat ions, ride slowly at first to get the f eel of the new handling characteristics.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 110 9.18 Adjusting vehicle lev el, front x Warning Danger of accident s Modifications to the cha ssis can seriously alter th e vehicle's handling cha racteristics. – Following modificat ions, ride slowly at first to get the f eel of the new handling cha racteristics.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 111 700353-01 – The fork legs can be fixed at th ree different positions. Guideline Upper triple clamp flus h with upper edge of fork legs 0 mm (0 in) Upper triple clamp flus h with 1st ring of fork legs 2.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 112 700331-01 – Loosen screw but do no t remove it. 700332-01 – Turn the eccentric shaf t to the desired position us ing the tool from the tool set.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 113 700334-01 – Tighten screw . Guideline Remaining chassis s crews M8 25 Nm (18.4 lbf ft) 9.20 Footrest position 700328-01 The adjustable footre st system enables an indiv idual setting of the footres t height and an individual adjustm ent of the operating elem ents.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 114 700307-01 – Remove screws . 700308-01 – Position the footrest bra cket with spacers and s crews. Guideline Standard Lower position Info The adjustable footre st bracket enables a more co mfortable lower footres t posi- tion or a sporting upper foo trest position.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 115 700309-01 – Repeat adjustment wo rk on the footrest bracket on th e other side. – Adjust the shift lever.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 116 9.22 Adjusting shift lever stu b 700304-01 – Remove the screw wit h the shift lever stub. – Position the shift lever st ub with the screw in one of the hol es according to the desired lever length.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 117 700343-01 – Remove screws and t ake off the shift rod. – The length of the shift rod ca n be adjusted by means of the s crew thread. Guideline Shift rod 115… 130 mm (4.53… 5. 12 in) – Loosen the counter nut s .
0 0 A A 0 0 B B 0 0 C C MAINTENA NCE WORK O N CHASSIS AN D ENGINE 118 400479-10 – The shift rod can be mount ed both on the shift lever varia bly at an upper or lower posi- tion, and on the reverse ge ar change of the shift shaft in two d ifferent positions.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 119 700344-01 – The position of the shift lev er can be greatly varied, dep ending on the length of the sh ift rod and the drill holes sele cted. As seen from the footre st, there is either a high positi on of the shift lever or a low p osition of the shift lever .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 120 9.24 Adjusting the footbra ke pedal stub 700305-01 – Remove the screw wit h the footbrake pedal stub . – Position the footbrake p edal stub with the screw in on e of the holes accordin g to the desired lever length.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 121 9.25 Adjusting the footbra ke pedal 700345-01 – Use the tool to press in the an ti-rotation lock , then t urn the piston rod . Info The range of adjustmen t is limited. – Remove the tool.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 122 9.27 Cleaning the chain Warning Danger of accident s Oil or grease on the tires redu ces their grip. – Remove oil and grease w ith a suitable cleaning mat erial. Warning Danger of accident s Reduced braking due to o il or grease on the brake discs .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 123 9.28 Checking the chain te nsion Warning Danger of accident s Danger caused by incor rect chain tension. – If the chain tension is too hig h, the components of the se condary power train (cha in, engine sprocket, rear sp rocket, bearings in transmission and rea r wheel) are under addition al load.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 124 9.29 Adjusting the chain ten sion Warning Danger of accident s Danger caused by incor rect chain tension.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 125 700323-01 – Loosen nut . – Loosen nuts . – Adjust chain tension by t urning the adjustment sc rews on the left and right.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 126 9.30 Checking rear spro cket / engine sprocke t for wear 100132-10 – Check the rear sprock et / engine sprocket for w ear. » If the rear sprocket / en gine sprocket are worn: – Change the rear sprock et / engine sprocket, chain a nd chain sliding guard.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 127 9.31 Checking chain wea r 700303-01 – Engage neutral gear. – Pull the lower chain secti on with specified weight . Guideline Weight, chain wear m easurement 15 kg (33 lb .) – Measure distance o f 18 chain links in the lower cha in section.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 128 9.32 Checking chain slid ing guard 700351-01 – Check the chain sliding g uard for wear at the opening. » If the rivets of the chain ar e no longer visible at the lowe r edge of the opening of the chain sliding guard : – Change the chain slidin g guard.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 129 9.34 Checking rear brak e disc Warning Danger of accident s Reduced braking effec t caused by worn brake disc s.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 130 9.36 Checking brake flui d level of front brake Warning Danger of accident s Failure of brake system . – If the brake fluid level falls b elow the MIN mark, there ma y be a leak in the brake system o r the brake linings are comp letely worn out.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 131 Warning Skin irritations Bra ke fluid can cause skin irrita tion on contact. – Avoid contact with skin a nd eyes, and keep out of the rea ch of children. – If brake fluid gets into your e yes, rinse thoroughly with w ater and contact a doctor im mediately.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 132 9.38 Brake linings The brake linings fitted b y KTM have been tested ove r long periods and guarant ee optimal braking chara cteristics. The type nam es of the brake linings are entere d in the homologation doc uments.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 133 700263-01 – Check the brake linings f or minimum thickness . Minimum thickness ≥ 1 mm ( ≥ 0.04 in) » If the minimum thickne ss is less than specified: – Change the front brake lin ings.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 134 700264-01 – Stand the vehicle uprig ht. – Check the brake fluid lev el of the brake fluid reservoir . » If the fluid level reaches th e MIN mark : – Top up the rear brake fluid. x ( S.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 135 Warning Environmental ha zard Problem materia ls cause environmenta l damage. – Dispose of oil, grease , filters, fuel, cleaning s ubstances, brake flui d, batteries, etc. accord ing to regulations. Info Never user DOT 5 bra ke fluid! This is based on silic one oil and is colored purple .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 136 Note Danger of accident s Reduced braking due to d amaged brake discs. – If the brake linings are not ch anged in time, the steel brak e lining carriers grind on the b rake disc. The braking effe ct is greatly reduced and the brake di scs are destroyed.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 137 700272-10 – Loosen screws and . – Unscrew screw abou t 6 turns, press your hand on th e screw to push the wheel spi n- dle out of the fork stub. Remo ve screw . Warning Danger of accident s Reduced braking effec t caused by damaged bra ke discs.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 138 700271-12 – Position the brake calip ers and check that the brake l inings are seated correc tly. – Mount and tighten scre ws .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 139 700311-01 – Remove nut . Remo ve chain adjuster . W ithdraw the wheel spin dle . 700312-01 – Push the rear wheel forwa rds as far as possible and take t he chain off the rear sprocke t.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 140 9.46 fitting the rear wheel x Warning Danger of accident s Reduced braking due to o il or grease on the brake discs . – Always keep the brake di scs free of oil and grease, and c lean them with brake clean er when necessary.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 141 700313-01 – Remove bushing an d bushing . Clean and g rease the roll surfaces of the b ushing and the shaft seal rings. Long-life grease ( S. 224) – Fit the bushings. – Clean the thread of the whe el spindle and nut.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 142 700315-01 – Push the rear wheel forwa rd as far as possible and place t he chain on the rear sprocke t. – Pull the rear wheel back an d push in the wheel spindle. 700316-01 – Lay the chain adjuster on the tensioning screw.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 143 9.47 Checking rear hub sh ock absorbers x Info The engine power is trans mitted by the rear sprocke t to the rear wheel through 5 sho ck absorbers. They are sub ject to wear during operation. If the shock ab sorbers are not changed in t ime, the rear sprocket carr ier and the rear hub are damag ed.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 144 Warning Danger of accident s Uncontrollable hand ling characteristics du e to non-approved and/o r non-recommended tir es/wheels. – Only tires/wheels app roved by KTM and with the corr esponding speed inde x should be used.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 145 9.49 Checking tire air pres sure Info Low tire air pressure lead s to abnormal wear and over heating of the tire. Correct tire air pressure e nsures optimal riding com fort and maximum tire se rvice life. 700268-01 – Remove dust cap.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 146 9.50 Removing the seat 700245-01 – Insert the ignition key in th e seat lock and turn it anticl ockwise.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 147 9.52 Removing passeng er seat 700246-01 – Remove the seat. ( S. 146) – Operate lever . – Take off the passenger s eat toward the top. 9.53 Fitting the passenger se at 700275-01 – Position the passeng er seat in the space provided .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 148 9.54 Mounting helmet lo ck on vehicle 700336-01 – Remove the seat. ( S. 146) – Position the steel cable f rom the toolset with one loop o n the lug . Steel cable (6001201 5000) – Guide the steel cable thro ugh the helmet opening.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 149 700276-10 – Disconnect the negat ive (minus) cable of the ba ttery. 700277-10 – Remove the plus pole co ver. – Disconnect the positi ve (plus) cable of the batt ery. 700278-01 – Remove screws .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 150 9.56 Installing the battery x 700279-01 – Position the battery in the b attery rack. Info The poles of the battery mu st face the rear of the vehicle. – Position the bracket . 700277-11 – Mount and tighten scre ws .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 151 700276-11 – Reconnect the negati ve (minus) cable of the ba ttery. – Fit the seat. ( S. 146) 9.57 Recharging the batt ery x Warning Risk of injury Batter y acid and battery gases cau se serious cauterizati on.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 152 Warning Environmental ha zard Problem materia ls cause environmenta l damage. – Dispose of oil, grease , filters, fuel, cleaning s ubstances, brake flui d, batteries, etc. accord ing to regulations. Info Even if there is no load on the ba ttery, it loses power every da y.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 153 100151-10 – Connect the battery cha rger to the battery. Switch on th e battery charger. Battery charger (584 29074000) You can also use the batte ry charger to test rest potenti al and start potential of the ba t- tery, and to test the genera tor.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 154 Info The main fuse protects a ll power-consuming com ponents of the vehicle. T he main fuse is under the seat . – Switch off all power-con suming components an d switch off the engine. – Remove the seat.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 155 9.59 Changing fuses of in dividual power consu mers Info The fuse box containin g the fuses of individual pow er consumers is located u nder the seat. – Switch off all power-con suming components an d switch off the engine.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 156 – Remove defective fus e. Guideline Fuse 1 - 10A - ignition, co mbination instrume nt, immobilizer, alarm s ystem (optional) Fuse 2 - 15A - high.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 157 Warning Fire hazard The elec trical system can be over loaded by the use of incorrec t fuses. – Use only fuses with the pre scribed amperage. Ne ver by-pass or repair fuses . – Use spare fuses with the c orrect rating only.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 158 700293-01 – Fold up the combinatio n instrument. Pull the lug out of the rubber holder . – Remove the rubber hold er. 700294-01 – Release the latch . – Remove the lamp cove r .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 159 700296-01 – Position the new headl ight bulb in the headlight hou sing. Low beam / high beam (H7 ) ( S. 213) Info Insert the headlight bul b so that the lug is position ed in the cut-out. – Position the retaining c lamp.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 160 700293-11 – Position the rubber hold er . – Fold down the combina tion instrument. Positio n the lug in the rubber ho lder. 9.61 Change the high beam bulb. Note Damage to reflector Keep the glass of the bulb fre e of grease.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 161 700297-01 – Remove screws . Re move cover. 700298-01 – Release the latch . – Remove the lamp cove r .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 162 700299-01 – Disconnect plug-in co nnector . – Push off the retaining cla mp on both sides, sque eze and fold to the side. – Remove headlight bu lb. – Position the new headl ight bulb in the headlight hou sing.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 163 400422-11 – Position the lug of the lam p cover in the notch. Engag e the latch. – Check lighting functio n. 700335-10 – Position cover. Info Check for correct positi oning and freedom of move ment of the brake lines.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 164 9.62 Changing the parkin g light bulb Note Damage to reflector Keep the glass of the bulb fre e of grease. – Clean the glass bulb with a c lean cloth before mountin g. Any grease on the glass wi ll evaporate by the heat and be d eposited on the reflector.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 165 700298-01 – Release the latch . – Remove the lamp cove r . 700300-01 – Pull the parking light c arefully out of the holder. – Remove the light bulb. – Position a new light bulb in t he holder.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 166 400422-12 – Position the lug of the lam p cover in the notch. Engag e the latch. – Check lighting functio n. 700335-11 – Position cover. Info Check for correct positi oning and freedom of move ment of the brake lines.
0 0 B B 0 0 A A MAINTENA NCE WORK O N CHASSIS AN D ENGINE 167 9.63 Checking headlig ht adjustment 400420-10 – On a light-colored wall be hind a horizontal area, mak e a mark as high as the center of the low beam headlight. – Make another mark at a dis tance of under the first m ark.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 168 700285-01 – Adjust the beam distan ce of the headlight by turning s crew . Guideline The boundary betwee n light and dark must be exact ly on the lower mark for a motor- cycle with a rider (mark is ap plied under: Checking he adlight adjustment).
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 169 – Switch on the ignition by tu rning the black ignition key t o the position . EFI warning lamp ( MIL ) lig hts up, switches off, and the n starts to flash. The immobilizer indicator la mp lights up, switches of f briefly, and switches on again.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 170 – Switch on the ignition by tu rning the orange program ming key to the position . EFI warning lamp ( MIL ) lig hts up, switches off, and the n starts to flash.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 171 – To activate further ignit ion keys, repeat the last 4 step s with the respective ignit ion key. – Insert the orange progra mming key in the ignition lo ck. – Switch on the ignition by tu rning the orange program ming key to the position .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 172 400416-10 Cooling takes place by m eans of the air stream and a rad iator fan , which is contr olled by a thermoswitch. The lower the speed, the le ss the cooling effect. Dirty co oling fins also reduce the c ooling effect.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 173 – Check the coolant leve l in the compensating tank . The coolant level mu st be between MIN and M AX . » If there is no coolant in the co mpensating tank: – Check the cooling syst em for leaks.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 174 Note Engine damage Aft er draining coolant and ref illing the cooling system , the motorcycle must be rai sed at the front according to th e model type. This is the only way of en suring that the cooling sys tem is filled without air bubb les.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 175 9.69 Adjusting basic posit ion of clutch lever 700283-01 – Adjust the basic setting o f the clutch lever to your hand s ize by turning adjusting screw . Info Turn the adjusting scre w clockwise to increase th e distance between the clu tch lever and the handleba r.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 176 700350-01 – Check the fluid level. The fluid level must be bet ween the MIN and MAX markings. » If the fluid level does n ot meet specifications : – Correct the fluid level o f the hydraulic clutch.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 177 9.72 Adjusting gas Bowd en cable x 700317-01 – Move the handlebar to th e straight-ahead positio n. – With the diagnostics to ol KTM DIA , place the con trol motor for the throttle valv e position into the neutral position .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 178 9.74 Adjusting handleb ar height Info The handlebar stub pos ition must be identical on th e left and the right of the vehicle . 700318-01 – Loosen screw . Info Loosen the screw seve ral turns to prevent damag ing the fork lacquer when mo v- ing the handlebar stub.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 179 700320-01 – Tighten the screw. Guideline Screw, handlebar stu b M8 20 Nm (14.8 lbf ft) – Repeat the adjustmen ts on the other handlebar stu b. – Move the handlebar to an d fro over the entire steering ra nge.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 180 9.76 Adjusting rear frame p osition Warning Danger of accident s Modifications to the cha ssis can seriously alter th e vehicle's handling cha racteristics. – Following modificat ions, ride slowly at first to get the f eel of the new handling cha racteristics.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 181 700327-11 – Remove screw with wa sher on the left and right side o f the vehicle. – Press the rear end up until th e drill holes of the frame are leve l with the lower rear drill holes of the frame rear .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 182 700338-01 – When you screw in the rea r left fixing screw, the plug-in c able binder is pushe d out of the thread. To reposi tion the cable of the lambda pr obe, fix the plug-in cable binder in the remaining fr ee drill hole.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 183 700327-14 – Remove screw with wa sher on the left and right side o f the vehicle. – Press the rear end up until th e drill holes of the frame are leve l with the upper front drill holes of the frame rear .
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 184 700338-11 – When you screw in the rea r left fixing screw, the plug-in c able binder is pushe d out of the thread. To reposi tion the cable of the lambda pr obe, fix the plug-in cable binder in the remaining fr ee drill hole.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 185 700301-10 – Remove oil dipstick . Check the engine oil leve l in the measurement rang e. Info After switching off the eng ine, wait one minute before c hecking the level. The engine oil level mus t be in the middle of the meas urement range of the oil dipstick.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 186 Warning Environmental ha zard Problem materia ls cause environmenta l damage. – Dispose of oil, grease , filters, fuel, cleaning s ubstances, brake flui d, batteries, etc. accord ing to regulations. Info Drain the engine oil only wh en the engine is warm.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 187 700287-01 – Stand the motorcycle o n its side stand on a horizonta l surface. – Place a suitable contai ner under the engine. – Remove the oil drain plug with the magnet, O-ring s and oil screen.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 188 700302-10 – Position the left exhaus t cover . – Mount and tighten scre ws . Guideline Remaining chassis s crews M5 5 Nm (3.7 lbf ft) 9.80 Removing oil filter x Warning Danger of scalding Engine oil and gear oil get ver y hot when the motocycle is d riven.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 189 Warning Environmental ha zard Problem materia ls cause environmenta l damage. – Dispose of oil, grease , filters, fuel, cleaning s ubstances, brake flui d, batteries, etc. accord ing to regulations. – Place a suitable contai ner under the engine.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 190 9.81 Fitting oil filter x 700291-01 – Insert the oil filter . – Lubricate the O-ring o f the oil filter cover. Fit the o il filter cover . – Mount and tighten scre ws. Guideline Remaining engine sc rews M5 6 Nm (4.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 191 – Remove the dipstick and top up the engine oil. Engine oil (1st quantity) 3.00 l (3.17 qt.) Ext ernal temperature: ≥ 0 °C ( ≥ 32 °F) Engine oil (SAE 10W/50) ( S. 222) External temperature: < 0 °C (< 32 °F) Engine oil (SAE 5W/40) ( S.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 192 Danger Danger of poisoning Exhaust gases are pois onous and can result in unconsciousness a nd/or death. – When running the engin e, always make sure there is s ufficient ventilation, and do not start or run the engi ne in a closed space.
MAINTENA NCE WORK O N CHASSIS AN D ENGINE 193 – Remove the dipstick and top up the engine oil. Condition External temperature : ≥ 0 °C ( ≥ 32 °F) Engine oil (SAE 10W/5 0) ( S. 222) Condition External temperatu re: < 0 °C (< 32 °F) Engine oil (SAE 5W/40 ) ( S.
TROUBLES HOOTING 194 10 TROUBLESHOOTING Faults Possible cause Action Engine doesn't crank w hen the electric starter button is presse d Operating error – Carry out the steps for start ing. ( S. 82) Battery discharged – Recharge the battery. x ( S.
TROUBLES HOOTING 195 Faults Possible cause Action Engine cranks but do esn't start Fuel pump contro l defective – Check fuel pump contro l. x Fuel quality insufficie nt – Add suitable fuel. Engine has too little powe r Air filter very dirty – Change the air filter.
TROUBLES HOOTING 196 Faults Possible cause Action Brake light and horn do not w ork Fuse 3 blown – Change the fus es of individual power consumers. ( S. 155) Battery discharged Ignition not switched of f when vehicle parked – Recharge the battery.
IMMOBILI ZER FLASH COD E 197 11 IMMOBILIZER FLASH CODE Fault Description Possible cause Action 12 Immobilizer indicator lamp flashes 1x short, 1 secon d pause, 2x short All ignition keys inactiv e – A ctivate/deactivate the i gni- tion key.
ENGINE CON TROL FLASH C ODE 198 12 ENGINE CONTROL FLA SH CODE Fault Description Possible cause Action 02 EFI Warning lamp ( MIL ) flashes 2x short Malfunction in ignitio n pulse generator circuit – Check the ignition puls e generator.
ENGINE CON TROL FLASH C ODE 199 Fault Description Possible cause Action 13 EFI Warning lamp ( MIL ) flashes 1x long, 3x short Input signal from inta ke air temperatur sensor to o high – Check the intake air temp er- ature sensor.
ENGINE CON TROL FLASH C ODE 200 Fault Description Possible cause Action 41 EFI Warning lamp ( MIL ) flashes 4x long, 1x short Interruption/short- circuit to ground in fuel pump cont rol circuit – Check fuel pump control. x Short-circuit to plus in fue l pump control circuit – Check fuel pump control.
ENGINE CON TROL FLASH C ODE 201 Fault Description Possible cause Action 62 EFI Warning lamp ( MIL ) flashes 6x long, 2x short Malfunction in idling co ntrol system – Check idle speed control.
CLEANING 20 2 13 CLEANING 13.1 Cleaning motorcyc le Note Material damage Damage and destructio n of components by high-p ressure cleaning equip ment.
CLEANING 20 3 Warning Danger of accident s Reduced braking due to w et or dirty brakes. – Clean or dry dirty or wet brake s by riding and braking gent ly. – After cleaning, ride a sho rt distance until operating t emperature is reached , and apply the brakes.
CONSERV ATION FOR WI NTER OPERA TION 204 14 CONSERVATION FOR WI NTER OPERATION 14.1 Conservation for wi nter operation Info If you use the motorcycle i n the winter, you have to expec t salt on the roads. You theref ore have to take precaution s against the aggressive road salt.
STORAGE 205 15 STORAGE 15.1 Storage Info If you want to garage the mot orcycle for a longer period, ta ke the following actions . Before storing the moto rcycle, check all parts for fun ction and wear. If service, re pairs or replacements ar e necessary, you should do this during the storage p eriod (less workshop ove rload).
STORAGE 206 – Cover the motorcycle w ith a porous sheet or blanket . Info Do not use non-porous m aterials since they preve nt humidity from escapin g, thus causing corrosio n.
TECHNICA L DATA - ENGINE 207 16 TECHNICAL DATA - ENGIN E Design 2-cylinder 4-stroke Ot to motor, 75° V arrangemen t, water-cooled Displacement 1,15 0 cm³ (70.
TECHNICA L DATA - ENGINE 208 3rd gear 20:30 4th gear 21:27 5th gear 23:26 6th gear 25:26 Mixture preparation Electronically contr olled fuel injection Ignition system Contactless control led fully electronic ignitio n with digital ignition adjustment Generator 12 V, 390 W Spark plug NGK LKAR9BI9 Electrode gap, spark pl ug 0.
TECHNICA L DATA - ENGINE T IGHTENING T ORQUES 209 17 TECHNICAL DATA - ENGINE T IGHTENING TORQUES Hose clip, intake flang e M4 1.5 Nm (1.11 lbf ft) – Screw, gear sensor M 5 3 Nm (2.2 lbf ft) Lo ctite ® 243™ Screw, pulse generato r M5 10 Nm (7.
TECHNICA L DATA - ENGINE T IGHTENING T ORQUES 210 Screw, stator clamp M6 10 Nm (7.4 lb f ft) Loctite ® 243™ Plug, vacuum connect ion M6 5 Nm (3.7 lbf ft) Lo ctite ® 243™ Screw, valve cover M6 10 Nm (7.4 lbf ft) – Screw, water pump co ver M6 10 Nm (7.
TECHNICA L DATA - ENGINE T IGHTENING T ORQUES 211 Screw, conrod bearing M10x1 Step 1 25 Nm (18.4 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 90° – Plug, cam lever axis M10x1 15 Nm (11.1 lbf ft) – Screw, cylinder head M11x1 .
TECHNICA L DATA - CHASS IS 212 18 TECHNICAL DATA - CHAS SIS Frame Lattice frame made of ch romium molybdenum s teel tubing, powder-coated Fork WP Suspension U p Side Down 4354 Shock absorber WP Suspension 401 4 VP Suspension travel front 120 mm (4.
TECHNICA L DATA - CHASS IS 213 Chain 5/8 x 5/16” X ‑ r ing Steering head angle 66.7° Wheelbase 1,435 m m (56.5 in) Seat height, unloade d Lower frame rear posi tion 805 mm (31.69 in) Upper frame rear pos ition 825 mm (32.
TECHNICA L DATA - CHASS IS 214 Brake/tail light LED License plate lamp W2,1x9,5d 12 V 5 W Front tire Rear tire 120/70 ZR 17 58 W T L Pirelli Dragon Supe rcorsa Pro 190/55 ZR 17 75 W T L Pirelli Dragon Supe rcorsa Pro For further information , see the Service section un der: http://www.
TECHNICA L DATA - FORK 215 19 TECHNICAL DATA - FORK Fork part number 05.18.7D.07 Fork WP Suspension U p Side Down 4354 Compression damp ing Comfort 15 clicks Standard 10 clicks Sport 5 .
TECHNICA L DATA - SHOCK A BSORBER 216 20 TECHNICAL DATA - SHOCK AB SORBER Shock absorber part n umber 17.18.7D.07 Shock absorber WP Suspension 401 4 VP Compression damp ing, high-speed Comfort 2 turns Standard 1.
TECHNICA L DATA - SHOCK A BSORBER 217 Spring length 160 mm (6.3 in) Gas pressure 10 bar (145 psi) Static sag 15 mm (0.59 in) Riding sag 30 mm (1.
TECHNICA L DATA - CHASS IS TIGHTENIN G TORQUES 218 21 TECHNICAL DATA - CHASSIS T IGHTENING TORQUES Screw, side stand switc h M4 2 Nm (1.5 lbf ft) Loctite ® 243™ Screw, brake fluid res ervoir of rear brake M5 5 Nm (3.7 lbf ft) Loctite ® 243™ Screw, brake line holde r M5 5 Nm (3.
TECHNICA L DATA - CHASS IS TIGHTENIN G TORQUES 219 Screw, front brake dis c M8 30 Nm (22.1 lbf ft) Loctite ® 243™ Screw, spring holder on s ide stand bracket M8 15 Nm (11.1 lbf ft ) Loctite ® 243™ Screw, rear footrest br acket M8 25 Nm (18.
TECHNICA L DATA - CHASS IS TIGHTENIN G TORQUES 220 Screw, connecting lev er, shock absorber deflector M10 45 Nm (33.2 lbf ft) Loctite ® 243™ Remaining chassis s crews M10 45 Nm ( 33.2 lbf ft) – Nut, deflection lever on f rame M14x1.
SUBSTAN CES 221 22 SUBSTANCES Brake fluid DOT 4 / D OT 5.1 according to – DOT Specification – Use only brake fluid that c omplies with the specifie d standards (see specifi cations on the container) a nd that possesses the cor re- sponding properties .
SUBSTAN CES 222 Engine oil (SAE 10W /50) according to – JASO T903 MA ( S. 226) – SAE ( S. 226) (SAE 10W/50) Specification – Use only engine oils tha t comply with the specified s tandards (see specific ations on the container) an d that possess the corresp onding properties.
SUBSTAN CES 223 Fork oil (SAE 5) according to – SAE ( S. 226) (SAE 5) Specification – Use only oils that compl y with the specified standa rds (see specifications o n the container) and that pos sesses the correspon ding prop- erties. KTM recommen ds Motorex ® products.
AUXILIARY S UBSTANC ES 224 23 AUXILIARY SUBSTANCES Chain cleaner Specification – KTM recommends M otorex ® products. Suppler Motorex ® – Chain Clean 611 Cleaning and polish ing materials for metal, r ubber and plastic Specification – KTM recommends M otorex ® products.
AUXILIARY S UBSTANC ES 225 Motorcycle cleane r Specification – KTM recommends M otorex ® products. Suppler Motorex ® – Moto Clean 900 Onroad chain spray Specification – KTM recommends M otorex ® products.
STANDAR DS 226 24 STANDARDS JASO T903 MA Different technical de velopment directions re quired a new specificat ion for 4-stroke motorcyc les – the JASO T903 MA Stan dard. Ear- lier, engine oils from the au tomobile industry were u sed for 4-stroke motorcy cles because there was no s eparate motorcycle sp ecification.
INDEX 227 INDEX B Battery f i t t i n g .................................... 1 5 0 r e c h a r g i n g ................................. 1 5 1 r e m o v i n g .................................. 1 4 8 Blank time of the LAP but ton LAP BLANK T a d j u s t i n g .
INDEX 228 E Electric starter butt on ............................. 2 3 Emergency OFF switc h ............................. 2 2 Engine r u n n i n gi n .................................. 7 8 Engine number .................................. 1 7 Engine oil c h a n g i n g .
INDEX 229 c h e c k i n g .................................. 1 6 7 Headlight flasher s witch ............................ 2 0 H e l m e t l o c k ................................... 7 4 f i t t i n gt o v e h i c l e ............................. 1 4 8 High beam bulb c h a n g i n g .
INDEX 230 P Parking ...................................... 8 8 Parking light bulb c h a n g i n g .................................. 1 6 4 Passenger footres ts ............................... 7 4 Passenger seat m o u n t i n g ........................
INDEX 231 Shock absorber part n umber ......................... 1 8 Side stand ..................................... 7 6 Spare parts, accesso ries ............................ 8 Starting ...................................... 8 2 S t e e r i n g d a m p e r .
KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com 02/2008 Photo Mitterbauer *32112 50en* 3211250en.
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