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12 service work on the chassis

1. 60 12 30 Checking the chain 61 12 31 Adjusting the chain tension 61 12 32 Checking the chain rear sprocket engine Sprocket and chain guide 62 12 33 Checking the frame 64 12 34 Checking the Swingarm 64 12 35 Checking the throttle cable routing 64 12 36 Checking the rubber grip 65 12 37 Additionally securing the rubber grip 65 12 38 Adjusting the basic position of the clutch EAT EE 65 12 39 Checking correcting the fluid level of the etel i uu uu a Deis vi Dana 65 12 40 Changing the hydraulic clutch fluid 66 12 41 Removing the trim 66 12 42 Mounting the trim 67 12 43 Removing the engine guard 68 12 44 Installing the engine guard 68 BRAKE SY x kanek S n y n 69 13 1 Checking the free travel on the hand brake IS EI T T M 69 13 2 Adjusting the free travel of the hand brake lcge E 69 13 3 Checking the brake 5 69 13 4 Checking the front brake fluid level
2. 70 rear brake adding ee 75 Brake fluid level front brake checking 70 rear brake checking 74 Brake linings front brake changing 72 front brake checking 71 rear brake changing 76 rear brake checking 75 C Capacities uwa Dey cas Puquy dr dk Y W W 89 104 CHSC Sex ya n XX e XU roS 94 104 u TTL 34 104 Chain CHOC RIP cea sk dod a ad EL RN RUN uU b a ACA 62 erol yy uyu etes at qo est otf MA SEQ 60 Chain guide CHECKS scs Suyupa puku a aaa uqi OO A EIE 62 Chain tension a acuit tab edet Brace us teur oe ote at 61 CHSC NING eh ee doa E Q ys Q 61 Chassis number 11 Gleanille seene eR Bek S xe ee Wu ia 96 97 Clutch fluid level checking correcting 65 H nang stu Sal ar CREAN S 66 Clutch 13 basic position adjusting 65 Compression damping TOL Kad 506 a aca og Ct ahi ROR AA A Wla ad 4 128 Compression damping high speed shock absorber adjusting s 38 Compression damping low speed shock absorber adjusting s 37 Coolant ez ET Mee Ab
3. 8 A VIEW OF VEHIOLE uu uuu uu xena 9 4 1 View of vehicle front left 9 4 2 View of vehicle rear right 10 5 SERIAL NUMBERS ala ka 11 Dal Chassis number 11 5 2 sua ne a Kek 1 1 5 3 Engine number 11 5 4 Key NUMDE 11 D Fork part number 11 5 6 Shock absorber part number 12 MEE amp ES Wan 13 6 1 Sei TUUM 13 6 2 Hand brake lever 13 6 3 Throttle grip 13 6 4 Kill SWITCH PME 13 6 5 SWIC u riba n wek n k k ICD RN PEERS a WANA 13 6 6 Turn signal switch 14 6 7 Forn DUELO DI inn uu uu S ak Kn n k xw n 14 6 8 Electric starter button 14 6 9 Indicator lamp 14 6 10 Fuel DUMP switch 15 DT a stes hor L9 6 12 Opening the filler caps 15 6 13 Closing the filler caps 16 6 14 Idle speed adjusting screw 17 6 15 S
4. Turn adjusting screws o clockwise all the way e Info Adjusting screws o are located at the bottom end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline Rebound damping standard 20 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce damp Ing Mount protection caps Q 11 14 Handlebar position The holes on the handlebar holders are placed at a distance of O from the center Distance between holes 3 5 mm 0 138 in The handlebar supports can be turned by 180 In this way the handlebar can be mounted in the position that is most comfortable for the rider The handlebar supports can also be mounted at two different heights with and without a spacer 402384 10 11 15 Adjusting the handlebar position A Warning Danger of accidents Handlebar breakage Ifthe handlebar is bent or straightened it will cause material fatigue and the handlebar can break Always replace handle bar 11 TUNING THE CHASSIS 4 402383 10 Remove the four screws Take off bracket Take off handlebar clamps with rubber washers and elastomers Fix the handlebar onto the instrument support with cable ties Info Protect the motorcycle and its attachments against damage by covering them Do not bend the cables and lines Remove the lower s
5. Sete Meas ah ok ast 89 POTTS fo ch ces od Oe Rate deb do hed hae UU oat a Doa deos 89 Coolant level CH OG S yp cs disset te RU eR Sew S eh RES RUNG 88 Cooling system 88 Customer service 8 E Electric starter button 14 Engine PUAN IN eate ie gs US DORT ata 30 Engine guards DD Re ENNE n 68 gala l a C Cn 68 Engine number quas y k K la wi us d ee 11 Engine oil ui xU DD DD 95 en D e e eeD eAeAeApAMMAMTRARMRToDDFBBa parar kuwa t eq 92 Engine oil level CHOC KIN E dae ar dnbio Ros ah Oe oss a rior t 92 Engine sprocket CHECKING aca anan ass d d 62 Environment 7 F dull m CI REMPLI 8 Filler caps CIOSIBB uris piace a ad ense at ku m ya mama 2 16 c y yusa bi e ked 15 Foot brake 17 free travel adjusting 74 free travel checking 3 Fork legs basic setting checking 41 bISedllE utbs S TOW Eu we db REESE 44 dust boots cleaning 45 nazil rusas ir ees RO eo e pace ea 46 Z Z Sos quint d pter acc ed 45 Frame CHECKING bo Aa hae kapa OE w S a N a Kek EA 64
6. 70 13 5 Adding front brake fluid 4 70 13 6 Checking the front brake linings 71 13 7 Changing the front brake linings 72 13 8 Checking the free travel of the foot brake i g OU TO 73 13 9 Adjusting the free travel of the foot brake r W gt _ oe a u u as 74 13 10 Checking the rear brake fluid level 74 13 11 Adding rear brake fluid 4 75 13 12 Checking the rear brake linings 75 13 13 Changing the rear brake linings 76 WE EEL TIRES uuu uu uu au cinn kokan kena dawi lan dan 78 14 1 Removing the front wheel A 78 14 2 Mounting the front wheel 78 14 3 Removing the rear wheel X 79 15 16 17 18 19 20 21 22 23 24 25 14 4 Installing the rear wheel 80 14 5 Checking the rear hub rubber dampers 81 14 6 Checking the tire condition 81 14 7 Checking the tire air pressure 82 14 8 Checking the spoke 82 ELECTRICAL SYSTEM ss u sla ul u l u ke a kulle 84 15 1 Removing the battery 4 84 15 2 Installing the battery 84 15 3 R
7. AP 6 Ar N rN 6 E8 or or br bl bl bl gr bl e HY 33 X10 bl br X41 IDV 2 M59 bl gr X42 DQ 2 2 1 DQ 2 X42 or bl bl B88 wa 1 FL 1 X65 gn gr gn gr X104 AD 12 BD 12 X103 7 gn gr P56 gn gr X64 FO 2 FO 2 X64 2 ye bu 4 E8 gt 6 F8 10 P gt 450 Rally Factory Replica 2015 D gt k 8 F1 gt L02808 10 24 WIRING DIAGRAM Components A11 B88 M59 P56 R54 Motor electronics control unit Oil pressure sensor Injector Oil pressure warning lamp CAN bus terminating resistor 121 122 24 WIRING DIAGRAM Page 8 of 8 24 8 A11 T A1 EJ HY 33 HY 33 c mHY 33 X10 X10 X10 in n E X24 X22 X23 JIF 2 2 FLA U U AT 2 B21 R51 B37 2 2 N X22 bu ye or gn ye pu pu B12 rd rd CM 2 j CM 2 bl IT F8 kP gt 450 Rally Factory Replica 2015 X25 X25 gt L02809 10 UE LIKAKAK Z VTI UUZUZ kLwrEaR _ j 24 WIRING DIAGRAM Components A11 B10 B12 B21 B26 B37 B41 R51 Cable colors bl br bu gn gr Ibu Or pk pu rd wh ye Motor electronics control unit Accelerator position sensor Intake air temperature sensor Engi
8. Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construc tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings If brake linings are used that differ from the originals there is no guarantee that they comply with the origi nal license The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid is corrosive Use only clean brake fluid from a sealed container Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Press the brake caliper by hand on to the brake disc in order to press back the brake pistons Ensure that brake fluid does not overflow from the brake fluid reser voir using suction to remove it if it does e Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes Remove cotter
9. Adjust the free travel of the foot brake lever p 74 Attach the spring to the foot brake lever A Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to overheating Adjust the free travel on foot brake lever according to specifications Loosen nut e and use screw o to adjust free travel Guideline Free travel at the foot brake lever 3 5b mm 0 12 0 2 in Hold screw o and tighten nut Guideline Remaining nuts chassis 10 Nm 7 4 Ibf ft Ifthe brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Stand the vehicle upright Check the brake fluid level in the brake fluid reservoir gt Ifthe fluid level reaches the MIN marking O Add rear brake fluid p 75 i s J f Yu 13 BRAKE SYSTEM 75 13 11 A Adding rear brake fluid A Warning Danger of accidents Failure of the brake system Ifthe brake flu
10. Screw connection spring holder at M6 10 Nm 7 4 Ibf ft Loctite 243 Side stand bracket Screw connection voltage regulator 8 Nm 5 9 Ibf ft Loctite 243 Screw bottom radiator bracket bottom radiator bracket M6 J5 Nm 3 7 Ibf ft DEED A brake fluid reservoir of rear C Nm 3 7 Ibf ft brake 23 TECHNICAL DATA 107 TEM chain sliding guard M6 6 Nm 4 4 Ibf ft Loctite 243 Screw engine guard bracket on engine 15 Nm 11 1 Ibf ft bearer Screw front brake disc M6 M Nm 14 Nm 10 3 Ibf ft 3 Ibf ft Loctite 243TM DL i6 ri br m n Screw seat older M6 seat lok lt 6 TT TT si nG 7 bin TT Tj o o y o Screw steering damor me TTTTT Screw steering damper baet we TT C Ts NLS Silentblock we _ Nut rear sprocket screw _ Na rimek TT TT Ta TT TT C O x Remaining screws chassis 25 Nm 25 Nm 18 4 lbf ft 4 bf ft Screw connection rear fuel tank bot u 25 Nm 18 4 Ibf ft 243 tom Screw bottom tipleclamp M 2Nm e 9brtt j lt Seewchansi ngpeee M8 enma _ _ Screw foot brake lever me 25 Nm 18 41br 10 lei __ Seen us j swe 0 front brake caliper 30 Nm 22 1 Ibf ft Loctite 243 mm LL Sew fultrkbeet we ISNn llhf _ Seewhader
11. 55 15 4 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never bypass or repair fuses e Info The main fuse protects all power consumers of the vehicle It is located in the starter relay housing under the seat Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 54 15 ELECTRICAL SYSTEM 86 Main work Remove protection cap Q Remove the faulty main fuse N y E 02794 10 Fita new main fuse Fuse 58011109130 p 105 e Info Replace a faulty fuse o by an equivalent fuse only A reserve fuse e Is located in the starter relay Check that the electrical equipment is functioning properly L02793 10 e Tip Insert the spare fuse so that it is avallable if needed Attach the protection caps Finishing work Mount the seat p 55 15 5 Changing fuses of individual power consumers e Info The fuse box containing the fuses of individual power consumers is located under the seat Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 54 Main work Push on locks and remove fuse box cover Remove the defective fuse Guideline Fuse 1 10 A spare fuse Fuse 2 10 A additional devices such as GPS permanent positive
12. 8 Winter operation checks and maintenance steps 97 Wiring diagram Paces 1 ODIO euo oat at n oes bra db v k SE aras 108 OF So lt k asia Ee Sal ELE dede e dla as 110 P389 SO SOLO aola An y iy tu eases ied eh aid 112 Pate OL Or Au a Res E SERT MUR SY eats 114 wir sa tet acu nd ar tede ka detail Sed orae 116 Pace OOo wawa s Mii u usa c M OUR S SRR eae 118 Pace OL O lt saha aa n ced ID kek ede RR han ek 120 QS JI usce at uc itd aw upaku ai ete k rr 122 Work TU S 3t AZ A arre ra tet a daa 130 WWW KTM COM 3213181 12 2014 TR zo Rai KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com KTM Group Partner Z Photo Mitterbauer KTM 12 100 6061
13. e Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes Loosen screws Remove screw Loosen screws 9 Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork e Info Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged Remove spacers Warning 4 Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Check the wheel bearing for damage and wear Ifthe wheel bearing is damaged or worn Change the wheel bearing 4 Clean and grease shaft seal rings and contact surface O of the spacers Clean and grease shaft seal rings and the contact surface of the wheel spindle Long life grease p 125 Insert spacers Position the front wheel and insert wheel spindle Z brake linings are correctly positioned Mount and tighten screw 9 Guideline Screw front wheel spindle M24x1 5 40 Nm 29 5 Ibf ft 14 WHEELS TIRES 19 e Info Ensure that the grip of the wheel spindle does not contact with the right fork leg Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc Remov
14. No function for 2 3 seconds Briefly press the Next display mode button Press the button No function for 2 3 seconds Briefly press the No function button 1 16 Display mode SPEED TR1 trip master 1 Repeatedly press the button briefly until TR1 appears at the top right of the dis play 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 400317 01 e Info If 999 9 is exceeded the values of TR1 A1 and S1 are automatically reset to 0 0 Press the button Displays of TR1 A1 and S1 are reset to 0 0 for 2 3 seconds Briefly press the Next display mode button Press the button No function for 2 3 seconds Briefly press the No function button 1 17 Display mode SPEED TR2 trip master 2 Repeatedly press the button briefly until TR2 appears at the top right of the dis play TR2 trip master 2 runs constantly and counts up to 999 9 Press the button Clears the values TR2 and AZ for 2 3 seconds Briefly press the Next display mode button 400323 01 400324 01 Press the button Reduces value of TR2 for 2 3 seconds Briefly press the Reduces value of TR2 button 7 18 Setting TR2 trip master 2 Condition e he motorcycle is stationary Repeate
15. e Info Do not clean the air filter with fuel or petroleum since these substances attack the foam Preparatory work Remove the seat p 54 Remove the air filter p 55 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 125 e Info Only press the air filter to dry it never wring it out Oil the dry air filter with a high quality filter oil 102745 01 Oil for foam air filter p 125 12 SERVICE WORK ON THE CHASSIS 56 Clean the air filter box Check the intake flange for damage and looseness Finishing work Install the air filter p 56 Mount the seat p 55 12 20 Installing the air filter A Preparatory work Remove the seat p 54 Remove the air filter A p 55 Clean the air filter and air filter box p 55 Main work Mount clean air filter Q e Info The air filter must lie flush against the air filter box along the entire sealing surface If the air filter is not correctly mounted dust and dirt can enter the engine and cause damage R _ U L02744 11 Mount and tighten screws 1 Finishing work Mount the seat p 55 12 21 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 Do not touch hot components Detach spr
16. tectie 24a 7 Seren state meta WN Suew migchntesoe M6 O oo o a Screw water pump cover cover M6 Nm 10 7 410 4 bf ft Oil nozzle for conrod bearing lubrica LOD 5 4 Nm 3 Ibf ft Wem T tion Pl qama 8 SNWGEBiU Screw rocker arm best n 15 Nm 11 1 Ibf ft RERRRE I Screw cylinder head M10x1 25 Step 1 Lubricated with engine oil 10 Nm 7 4 Ibf ft Step 2 30 Nm 22 1 Ibf ft Step 3 50 Nm 36 9 Ibf ft Nut rotor M12x1 60 Nm 44 3 Ibf ft Thread oiled with engine oil cone degreased Spark plug M12x1 25 15 20 Nm 11 1 14 8 Ibf ft Wins aon eg Pug oll pressure reguator MI18 20Nm ABM TT _ Nat iner cluteh hub Mi amp is eomme TTTT Screw plug o l screen MOds TT O 23 TECHNICAL DATA 104 23 3 Capacities 23 3 1 Engine oil Total filling level oil 1 40 1 48 qt Engine oil SAE 10W 50 p 124 change Total filling level engine 1 80 I 1 9 qt Engine oil SAE 1OW 50 p 124 service with oil radiator 23 3 2 Coolant L21 8 qt Coolant p 124 23 3 3 Fuel Fuel tank capacity Fuel tank half front left 7 5 1 98 US gal Super unleaded ROZ 95 RON 95 PON 91 p 124 approx Fuel tank half front right 7 5 1 1 98 US gal Super unleaded ROZ 95 RON 95 PON 91 p 124 approx R
17. 50 EC x sla pumapa KN muya sua au QO 2L A 49 Steering lock 18 Storape pe d wed EK Wauqe qea wa ae Mn 98 INDEX Swingarm Chec KIDIB queue Eus ap de a dirt o c 64 T Technical data of saa said e n ke ar diken re ke e Qay E ufo des 104 104 chassis tightening torques 106 electrical Systemi ute site eec me OT RR e es 105 ped apr 105 DD eem 102 motor tightening torques 102 SNOCK absorber 47 a dac XWA MY urhe EEE CES 106 UO Scavi uoi tad toot ted dct cci tet CUR eee 105 Throttle cable routing Chic MIB zo CER RT ar eh a SG af dod Se LES UMS RO 64 TIL OL le DID s iu sara AES atatum d pusa 13 Tire air pressure ku docuit a ace bulaq ee ot e ds OP ACC d 82 Tire condition ene Saw doc se RO AE OE ea rat n 81 iran BB dd 33 Trim FO UII Stai USD BNN 67 EMON Gs Qs ardor tot Se 66 Troubleshooting 99 100 Turn signal switch 14 Type label 2 t n l d bleo o 11 U Use definitlol iio ky an kw kya ware eie uswa uraqa 6 V View of vehicle KONNIE Sob QE k a Z amu p Soe dawn Gere ee 9 Keg PEDE manaa h atur Som Ste i met as D te ao eo re ka 10 W Wana RETE NETT ae Scat rete ds ae ea Sat Se ate
18. Hook wrench T106S Measure the overall spring length when not under tension ighten the spring by turning adjusting ring o to measurement O Guideline Spring preload Standard 12 mm e Info Depending on the static sag and or the riding sag it may be necessary to increase or decrease the spring preload s ammo aa Tighten screw Q Guideline Screw shock absorber adjusting ring 5 Nm 3 7 Ibf ft Finishing work Install the shock absorber amp p 52 Install the main silencer p 56 Mount the seat p 55 Remove the motorcycle from the lift stand p 44 402405 10 11 10 Adjusting the riding sag Preparatory work Raise the motorcycle with the lift stand p 44 Remove the seat p 54 Remove the main silencer p 56 Remove the shock absorber amp p 51 After removing the shock absorber clean it thoroughly Main work Choose and mount a suitable spring B00292 10 11 TUNING THE CHASSIS 41 Guideline Spring rate Weight of rider soft 65 75 kg 51 N mm 291 Ib in 143 165 Ib Weight of rider standard 75 54 N mm 308 Ib in 85 kg 165 187 Ib Weight of rider hard 85 95 kg 57 N mm 325 Ib in 187 209 Ib e Info The spring rate is shown on the outside of the spring Smaller weight differences can be compensated by changing the spring preload Finishing
19. Fuse 3 10 A high beam low beam parking light tail light license plate lamp speedometer horn Fuse 4 10 A Iritrack Fuse 5 10 A Road Book Fuse 6 10 A brake light turn signal Fuse 7 10 A radiator fan Fuse 8 10 A start system e Info A defective fuse is shown by a burned out fuse wire Q 15 ELECTRICAL SYSTEM 87 Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never bypass or repair fuses Use spare fuses with the correct rating only Fuse 58011109110 p 105 Check that the power consumer is functioning properly Close the fuse box cover Finishing work Mount the seat 55 16 COOLING SYSTEM 88 16 1 Cooling system Water pump in the engine circulates the coolant The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap 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 cool ing effect 02797 10 The radiator fan provides extra cooling It is controlled by a thermoswitch 16 2 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation the coolant gets very ho
20. Material damage Damage and destruction of components by high pressure cleaning equipment When cleaning the vehicle with a pressure cleaner do not point the water jet directly onto electrical components connectors cables bearings etc Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component Excessive pressure can cause malfunctions or destroy these parts Warning Environmental hazard Hazardous substances cause environmental damage Dil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in 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 Close off the exhaust system to keep water from entering Remove loose dirt first with a soft jet of water Spray very dirty parts with a normal commercial engine cleaner and then brush off with a soft brush Motorcycle cleaner p 125 e Info Use warm water containing normal motorcycle cleaner and a soft sponge 401061 01 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 Remove the closure of the exhaust system Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a di
21. Read out the fault memory using the KTM diag nostics tool Faulty ignition system Ignition coil check the secondary winding Check the spark plug connector Check the stator winding of the alternator Engine has too little power Air filter is very dirty Clean the air filter and air filter box p 55 Fuel filter is very dirty Change the fuel filter Defect in the fuel injection system Read out the fault memory using the KTM diag nostics tool Exhaust system leaky deformed or Check exhaust system for damage too little glass fiber yarn filling in Change the glass fiber yarn filling of the main main silencer silencer p 57 Valve clearance too little Adjust the valve clearance Faulty ignition system Ignition coil check the secondary winding Check the spark plug connector Check the stator winding of the alternator The engine dies during the trip Lack of fuel Fill up with fuel p 34 Engine overheats Too little coolant in cooling system Check the cooling system for leaks Check the coolant level p 88 Too little air stream Switch off the engine when standing Radiator fins very dirty Clean the radiator fins Foam formation in cooling system Drain the coolant 89 Refill the coolant p 89 Bent radiator hose Change the radiator hose Thermostat defective Check t
22. X52 X53 X69 X70 X19 r 1 56 X56 e J EB 4 EB 4 1CJ 2 CJ 2 AH 2 IFH16 FH 16 A T u X101 n X81 2 e X103 el o C142 E63 E64 P35 AH 2 F1 5 F1 4 lBD 12 T T s amp 1 U o e CC 12 il i AD 12 X102 X104 NI N N X82 LO 2 EB A EB A I CJ 2 CJ 2 AH 2 2 oFH 16 SIFH 16 X52 X53 X69 X70 X19 1 X56 X56 5 s g P885 5 5 5 zB 3E8 f gt 3 B8p IE 3 E8 bD gt gt lo 6 F1 1 F8 bo e gt lb 5 E1 3 F8 L 7 E1 gt SS 2 E8 be gt 5 1 v Q v x x br br 12 12 3 E8 o E NA UN gt 6 F1 es Sc Xo X 3 F8 F9 D 40 450 Rally Factory Replica 2015 F9 5 B1 C gt L02805 10 24 WIRING DIAGRAM Components F63 Low beam F64 High beam Fl 4 Fuse F1 5 Fuse K33 High beam relay K35 Low beam relay P35 Parking light 115 116 24 WIRING DIAGRAM Page 5 of 8 24 5 255 D 1 D8 mil gt Qh P62 gt L02806 10 wh rd 4 E8 gt 4 E8 lo P gt gn rd gn rd br 0 or br br b br br br br aa 5 C MN ji 450 Rally Factory Replica 2015 uum 24 WIRING DIAGRAM Components F1 2 Fuse K20 Turn signal relay P21 Turn signal indicator light P41 Front left turn signal P42 Front right turn signal P45
23. p 67 Install the front fender p 54 Mount the front wheel p 78 Check the steering head bearing play p 49 Remove the motorcycle from the lift stand p 44 12 9 Checking the steering head bearing play Warning Danger of accidents Unstable vehicle handling from incorrect steering head bearing play Adjust the steering head bearing play without delay Your authorized KTM workshop will be glad to help e Info I If the bike is ridden with play in the steering head bearing the bearing and the bearing seats in the frame can become dam aged over time Preparatory work Raise the motorcycle with the lift stand p 44 Main work Move the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel No play should be noticeable in the steering head bearing gt If there is noticeable play present Adjust the play of the steering head bearing p 50 Move the handlebar to and fro over the entire steering range The handlebar must be able to move easily over the entire steering range No resting locations should be noticeable gt f click positions are noticeable Adjust the play of the steering head bearing p 50 Check the steering head bearing and replace if required Finishing work Remove the motorcycle from the lift stand p 44 12 SERVICE WORK ON THE CHASSIS 5 e 12 10 Ad
24. 39 0 79 in edge of boot Ifthe distance does not meet specifications Adjust the basic position of the shift lever p 91 400692 10 Remove screw Q and take off shift lever 401950 12 Clean gear teeth O of the shift lever and shift shaft Mount the shift lever on the shift shaft in the required position and engage the gearing e Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle compo nents during the shift procedure 401951 10 Mount and tighten screw Guideline Screw shift lever M6 14 Nm Loctite 243 10 3 Ibf ft 18 SERVICE WORK ON THE ENGINE 92 18 1 Checking the engine oil level 555550 Condition The engine is at operating temperature Preparatory work Stand the motorcycle upright on a horizontal surface Condition The engine is cold Check the engine oil level e Info After switching off the engine wait a minute and then check The engine oil level is between O and _ 1102800 10 gt When the engine oil level is below the O marking Add engine oil p 95 gt When the engine oil level is at or above the marking Correct the engine oil level A Warning m Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm wate
25. Front fender dismounting at front 54 SEAMING at MONT arrai c n ruo Gaye ae es ce Wa 54 Front left fuel tank IS tal Ig e aoc 2 Sy mu does CR e ER 59 sc ORO C RR 5 Front right fuel tank s dioe aber ar prato te deat Roe etate eae fe 60 LOO VIRI s y mun AA telo o Kek upa u rates 58 Front wheel Dir 78 Toa e MERECE muta sua a ka p mao em aa 78 INDEX Fuel pump switch 15 dli ane NH WW 15 Fuse main fuse changing 85 of individual power consumer changing 86 H Hand brake lever 13 fr e travel adjuStltig Sog ote A Rew 69 free travel checking 69 Handlebar position 42 JU EE pe TREES a Z EA 42 HOM PUNON aaa sag kao les Wa RE UNUS 14 l Idle speed ud take RR aa alava 91 Idle speed adjusting screw 17 Indicator lamp overview 14 Intended use 6 K Key number 11 KII SWARO s lena ke an ya P a atan Son e oos 13 L Lie lit SWIEGIE s gt HE wu adir ELE dod beg de C olo a kj 13 Lower triple clamp Z
26. Rear left turn signal P46 Rear right turn signal P62 Speedometer 525 Turn signal switch 117 118 24 WIRING DIAGRAM Page 6 of 8 24 6 A11 12 2 7 A1 14 88 d D rd or or _ 2 j 3 j 4 j 08 j 8 7 al 10 X10 bu gr bu gr HY 33 co 8 COH2 X102 pu gn bu gn X101 CI 12 GA bu gn or bl bu bl bu X35 3 Im UJ K EB 4 X35 M13 br br rd br X37 br br rd X102 gt CC 12 o CI 12 X101 q pu gn bl pu bl pu X36 2 3 m UJ Ew M58 EB 4 X36 or or bl pu br bl pu X33 CA 4 EN 4 N CA 4 X33 2 rd pu br br L or 7 E1 X56 FEH 16 a F1 8 5 NU FH 16 D X56 1 F8 or gt E 4 E6 10 gt 4 F8 10 gt 450 Rally Factory Replica 2015 L gt 7 E1 gt L02807 10 24 WIRING DIAGRAM Components A11 Motor electronics control unit F1 8 Fuse K31 Relay for rear fuel pump K32 Relay for front fuel pump M13 Rear fuel pump M58 Front fuel pump P50 Low fuel warning lamp for rear fuel tank P51 Low fuel warning lamp for front fuel tank S57 Fuel pump switch 119 120 24 WIRING DIAGRAM Page 7 of 8 24 7 wh bu wh bu bl bu bl rd bl bu wh bu br or X31 AT 2 1 2 X32 S
27. Store fuel properly in a suitable canister and keep away from children Preparatory work Remove the seat p 54 Remove the trim p 66 Remove the engine guard p 68 Main work Clean the plug in connection of the fuel line thoroughly with compressed air e Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Disconnect the plug in connection of the fuel line LO2746 10 12 SERVICE WORK ON THE CHASSIS 59 Mount wash cap set o from the separate enclosure Wash cap set 81212016100 Detach fuel tank breather hose Remove screws off the fuel tank e Info Set the fuel tank down in an upright position as otherwise fuel can escape from the fuel tank breather at the filler cap 12 26 Installing the front left fuel tank A Main work Position the fuel tank Mount and tighten screws Q Guideline Screw front fuel tank 8 Nm 5 9 Ibf ft Mount fuel tank breather hose Remove the wash cap set Clean the plug in connection e of the fuel line thoroughly with compressed air e Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Lubricate the O ring and connect plug in connection of the fuel line Connect the plug in connection of fuel pump Remove the wash cap set Clean the plug
28. case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swal lowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Condition The engine is cold Stand the motorcycle upright Place a suitable container under the water pump cover Remove screw Q Remove radiator cap Completely drain the coolant Mount and tighten screw with new seal ring Guideline Screw water pump cover 10 Nm 7 4 Ibf ft 16 5 Refilling coolant A Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swal lowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Make sure that screw Is tightened Stand the motorcycle upright Pour coolant in up to measurement O above the radiator fins Nu Guide
29. connection of the fuel line thoroughly with compressed air e Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Disconnect the plug in connection of the fuel line Mount the wash cap set from the separate enclosure Wash cap set 81212016100 Disconnect plug in connection o of the fuel pump Detach fuel tank breather hose Q Remove screws Q Take off the fuel tank e Info Set the fuel tank down in an upright position as otherwise fuel can escape from the fuel tank breather at the filler cap 12 25 Removing the front right fuel tank Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel
30. dampers p 81 Check the wheel bearing for damage and wear Ifthe wheel bearing is damaged or worn Change the wheel bearing Clean and grease shaft seal ring eo and contact surface O of the spacer Long life grease p 125 Insert the spacer Clean and grease the spacers of the rear sprocket carrier Insert the rear sprocket carrier o into the rear hub Position the rear wheel and insert wheel spindle 9 Z brake linings are correctly positioned Attach the chain Position chain adjuster Mount nut but do not tighten it yet Check the chain tension p 61 Make sure that the chain adjusters are fitted correctly on the adjusting screws Q Tighten nut Q9 Guideline Nut rear wheel spindle M25x1 5 90 Nm 66 4 Ibf ft Info I The wide adjustment range of the chain adjusters enables different sec ondary ratios with the same chain length Chain adjusters o 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 44 14 WHEELS TIRES 81 14 5 Checking the rear hub rubber dampers e Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers They eventually wear out during operation If the rubber dampers are not changed in time the re
31. down Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Move the brake fluid reservoir mounted on the handlebar to a horizontal position Check the brake fluid level in the viewer gt Ifthe brake fluid has dropped below marking O Add brake fluid of the front brake p 70 13 5 Adding front brake fluid A Warning Danger of accidents Brake system failure If the brake fluid level drops below the specified marking or the specified value this is an indication that the brake system Is leaking or that the brake linings are completely worn down Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles f brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service sched
32. for cuts foreign bodies and other damage f you find cuts foreign bodies or other damage on a tire Change the tire Check the depth of the tread e Info Note local national regulations concerning the minimum tread depth 400602 10 Minimum tread depth 22mm gt 0 08 in Ifthe tread depth is less than the minimum allowable depth Change the tire Check the tire age 14 WHEELS TIRES 82 Info The tire manufacture date is usually included in the tire identification num ber and comprises the last four digits of the DOT code The first two digits indicate the week of manufacture and the last two digits the year of manu facture KTM recommends that the tires be changed after 5 years at the latest regardless of the actual state of wear Ifthe tire is older than five years Change the tire 14 7 Checking the tire air pressure e Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life Remove the dust cap Check tire air pressure when tires are cold Tire air pressure off road L 5 bar 22 ps L 5 bar 22 ps Ifthe tire pressure does not meet specifications 400695 01 Correct the tire air pressure Fit the dust cap 14 8 Checking the spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that
33. is correctly positioned Slide on protective ring and O ring 402412 10 12 SERVICE WORK ON THE CHASSIS 4 Position the upper triple clamp Mount screw o but do not tighten yet Position the fork legs v Bleeder screws 5 are positioned toward the front e Info The fork legs must be flush with the upper edge of the upper triple clamp Tighten screws Q Guideline Screw bottom triple clamp 12 Nm 8 9 Ibf ft Secure the brake line on the fork leg with cable binder Mount and tighten screw Q Guideline Screw brake line holder on bottom M5 2 Nm 1 5 Ibf ft triple clamp Tighten screw Guideline Screw top steering head M20x1 12 Nm 8 9 Ibf ft Tighten screw D Guideline Screw top steering stem M8 20 Nm 14 8 Ibf ft Tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 Ibf ft 12 SERVICE WORK ON THE CHASSIS 49 Remove cable tie s and place the handlebar onto the handlebar clamp base Position the steering damper Mount and tighten screws Guideline Screw steering damper M6 15 Nm 11 1 Ibf ft Mount the holding plate with the handlebar clamps and position the handlebar Mount and tighten screws Guideline Screw handlebar clamp M8 16 Nm 11 8 Ibf ft Finishing work Check that the wiring harness cables and brake and clutch lines can move freely and are routed correctly Mount the trim
34. of components Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces can lead to considerably more rapid 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 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 dis assemble the component to perform the activity in question Please follow the instructions in the text 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 OF VEHICLE 9 WS Clutch lever p 13 Seat release strap Shift lever p 17 Side stand p 18 GW N 4 OF VEHICLE 10 4 2 View of vehicle rear right LO2701 10 Kill switch p 13 Light switch p 13 Turn signal switch p 14 Horn button p 14 Fuel pump switch p 15 Electric starter button p 14 Throttle grip p 13 Speedometer overview
35. pin 13 BRAKE SYSTEM 73 Drive out pin O with drift O toward the rim and remove the brake linings Clean the brake caliper and brake caliper support Check that leaf spring O in the brake caliper and sliding plate Q in the brake caliper support are seated correctly Insert the new brake linings insert pin and mount cotter pin Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Add brake fluid to level Guideline Measurement of 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 124 Position cover o with membrane Mount and tighten screws Q e Info Clean up overflowed or spilt brake fluid immediately with water p A 7 02769 10 13 8 Checking the free travel of the foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to overheating Adjust the free travel on foot brake lever according to specifications 13 BRAKE SYSTEM 74 Detach the spring from the foot brake lever 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 Guideline Free travel at the foot brake lever 3 5b mm 0 12 0 2 in Ifthe free travel does not meet specifications
36. sharp bends Change the glass fiber yarn filling of the main silencer p 57 O e e e O e e e O e e e e e e e e e e e e Final check Check the vehicle for roadworthiness and take a test ride Read out the error memory after the test ride using the KTM diagnostics tool Make the service entry in KTM Dealer net and in the service record 10 SERVICE SCHEDULE 36 o One time interval e Periodic interval 10 2 Service work as additional order Annually after every race Every 100 operating hours Every 50 operating hours Every 40 operating hours Once after 20 operating hours e e e e e e e e e e e e One time interval Change the suction pump e Periodic interval 11 TUNING THE CHASSIS 37 11 1 Checking the basic chassis setting with the rider s weight e Info When adjusting the basic chassis setting first adjust the shock absorber and then the fork For optimal motorcycle riding characteristics and to avoid damage to forks shock absorbers swingarm and frame the basic settings of the suspension components must match the rider s weight As delivered KTM offroad motorcycles are adjusted for a standard rider weight with full protective clothing Guideline Standard rider weight 75 85 kg 165 187 Ib Ifthe rider s weight is above or below this range the basic setting of the suspen sion components must be adjusted ac
37. should only be used by trained persons An appropriate driver s license is needed to ride the vehicle on public roads Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop Adhere to the information and warning labels on the vehicle 2 6 Protective clothing Warning Risk of injury Missing or poor protective clothing presents an increased safety risk Wear protective clothing helmet boots gloves pants and jacket with protectors every time you ride the vehicle Always wear protective clothing that is in good condition and meets the legal requirements In the interest of your own safety KTM recommends that you only operate the vehicle while wearing protective clothing 2 7 Work rules Special tools are necessary for certain tasks The tools are not contained in the vehicle but can be ordered under the number in paren theses E g bearing puller 15112017000 During assembly non reusable parts e g self locking screws and nuts seals and seal rings O rings pins lock washers must be replaced by new parts In some instances a thread locker e g Loctite9 is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them for damage and wear Change damaged or worn parts After you complete the repair or service work check the operating safety of the vehicle 2 8 Environment If you use your motorcycle responsibly you c
38. signal do not Fuse 6 is blown Change the fuses of individual power work consumers p 86 22 BLINK CODE Blink code of Fl warning lamp MIL 101 02 warning lamp MIL flashes 2x short Error level condition Crankshaft position sensor circuit fault Blink code of Fl warning lamp MIL Error level condition Blink code of Fl warning lamp MIL Error level condition Blink code of Fl warning lamp MIL Error level condition Blink code of Fl warning lamp MIL Error level condition Blink code of Fl warning lamp MIL Error level condition Blink code of Fl warning lamp MIL 06 FI warning lamp MIL flashes 6x short Throttle position sensor circuit A input signal too low Throttle position sensor circuit A input signal too high 09 FI warning lamp MIL flashes 9x short Manifold absolute pressure sensor cylinder 1 input signal too low Manifold absolute pressure sensor cylinder 1 input signal too high 12 Fl warning lamp MIL flashes 1x long 2x short Engine coolant temperature sensor input signal too low Engine coolant temperature sensor input signal too high 13 warning lamp MIL flashes 1x long short Intake air temperature sensor input signal too low Intake air temperature sensor input signal too high 15 FI warning lamp MIL flashes 1x long 5x short Rollover sensor A D type input signal too low Rollov
39. specified measurement Change the drivetrain kit e Info Vo _ X I When the chain is replaced the rear sprocket and engine sprocket CLL 9 o Should also be changed 12 3 16 17 18 New chains wear out faster on old worn sprockets 400987 10 12 SERVICE WORK ON THE CHASSIS 63 Check the chain sliding guard for wear Ifthe bottom edge of the chain bolt is in line with or below the chain sliding guard Change the chain sliding guard Check that the chain sliding guard is firmly seated Ifthe chain sliding guard is loose ighten the chain sliding guard Guideline Screw chain sliding M6 6 Nm Loctite 243 guard 4 4 Ibf ft LO2758 10 Check the chain sliding piece for wear Ifthe bottom edge of the chain bolt 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 ighten the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 Ibf ft Check the chain guide for wear e Info Wear is visible on the front of the chain guide Ifthe chain guide is worn Change the chain guide Check that the chain guide is firmly seated Ifthe chain guide is loose Tighten the chain guide Guideline Remaining screws chassis 10 Nm 7 4 Ibf ft Remaining nuts chassis M6 10 Nm 7 4 Ibf f
40. stand p 44 Main work Push the chain upward at the end of the chain sliding guard to measure chain ten sion Q e Info The upper chain section must be taut Chain wear is not always even so you should repeat this measurement at different chain positions L02756 10 gt Ifthe chain tension does not meet specifications Adjust the chain tension p 61 Finishing work Remove the motorcycle from the lift stand p 44 12 31 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain is too taut the components of the secondary power transmission chain engine sprocket rear sprocket bear ings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme cases If the chain is too loose however it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine Ensure that the chain tension is correct and adjust it if necessary Preparatory work Raise the motorcycle with the lift stand p 44 12 SERVICE WORK ON THE CHASSIS 62 Main work Loosen nut Loosen nuts Adjust the chain tension by turning adjusting screws left and right Guideline Turn adjusting screws on the left and right so that the markings on the left and right chain adjuste
41. stop watch If S2 is running in the background the display S2 flashes on the speedometer ress the button The displays of S2 and A2 are set to 0 0 for 2 3 seconds 400327 01 Briefly press the Next display mode button 400328 01 Press the button No function for 2 3 seconds Briefly press the Starts or stops S2 button 1 23 Table of functions Display Press the but Briefly press the Press the but Briefly press the Wait 3 5 sec Wait 10 12 sec ton for 2 3 button ton for 2 3 button onds onds seconds seconds Display mode The display Next display No function No function SPEED H service changes to the mode hours Setup menu of the speedome ter functions Setup menu No function Activates the No function Deactivates the Changes to the Setup menu flashing display flashing display next display starts stores and changes to and changes to without changes the settings the next display the next display and changes to H or ODO Setting the unit of No function Starts selection No function Activates Mph Changes to the Saves and activates Km h display measurement display next display closes the Setup changes from menu selection to the Setup menu The display Next display No function No function changes to the mode Setup menu of the clock setting the clock Increases the Increases the Reduces the Reduces the Changes to the Closes t
42. text and are referred to at the relevant passages Info The vehicle has various information and warning labels at prominent locations Do not remove information warning labels If they are missing you or others may not recognize dangers and may therefore be injured 2 3 Degrees of risk and symbols Danger A Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution A Indicates a danger that may lead to minor injuries if the appropriate measures are not taken Note Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken Warning it Indicates a danger that will lead to environmental damage if the appropriate measures are not taken 2 4 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 maintenance 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 inope
43. tt tie ad t a6 a em E t HHH HH o uc 47 S OV E 46 M Main fuse Chanel O kulk 99 9 8 0 8 x an uf doe er ded e UB waa e 85 Main silencer glass fiber yarn filling changing 57 c io Se apiid ata tor we ilu ad wy he ie osea 56 OV P E 56 Motorcycle BIN PORE 96 raising with lift stand 44 removing from lift stand 44 0 Dil filter CANIS a HRH HRH HHHH HHHH HHHH e HHH reme 92 0il screens oe ed hy ca rac eW eee Se 92 Operating substances 8 Owner s Manual P Play in throttle cable 90 CCC WN d UO aba 90 Preparing for use advice on first use 29 Alter SIOVACE quta dodo A RAO CECI gus eS D CA oa 98 checks and maintenance when preparing for use 31 Protective clothing 7 129 R Rear hub rubber dampers CCC KAWA e ta eat go decathlon do SR dr diode a W N 81 Rear sprocket CECA Luya ariya NIME dest eod KE sr We RU S 62 Rear wheel STANIE eaaa parv d D dic 80 FEMOVNE z Gu Se paru Ban m 79 Rebound damping SEM S Ea NNN 42 shock absorber adjusting n 38 Refueling TUO uugixeu b ERES mue d di s 34 Riding sag LCL PIS UMN cries rwr afta nde att Ear y e Me
44. unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed Space without an effective exhaust extraction system Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always warm up the engine at low engine speeds Take the motorcycle off the side stand and secure the side stand with the rub ber band Shift gear to neutral 401944 10 Press the electric starter button e Info l Press the electric starter button for at most 5 seconds Wait for a least 5 seconds before trying again Fl warning lamp lights up briefly as a function check when starting 400733 01 9 RIDING INSTRUCTIONS 32 9 3 Starting off e Info Switch on the light before riding the motorcycle You will then be seen earlier by other motorists When you are riding the side stand must be folded up and secured with the rubber band Pull the clutch lever engage 1st gear release the clutch lever slowly and simultaneously open the throttle carefully 9 4 Shifting riding Warning Danger of accidents f you change down at high engine speed the rear wheel can lock up Do not change into a low gear at high engine speed The engine races and the rear wheel can lock up e Info If you hear unusual noises while riding stop immediately switch off the engine and contact
45. work Install the shock absorber p 52 Install the main silencer p 56 Mount the seat 55 Remove the motorcycle from the lift stand p 44 Check the static sag of the shock absorber p 39 Check the riding sag of the shock absorber p 39 Adjust the rebound damping of the shock absorber p 38 11 11 Checking the basic setting of the fork e Info For various reasons no exact riding sag can be determined for the forks 401000 01 As with the shock absorber small differences in the rider s weight can be compen sated by the spring preload However if the fork is often overloaded hard end stop on compression harder springs must be fit to avoid damage to the fork and frame 11 12 Adjusting the compression damping of the fork e Info The hydraulic compression damping determines the fork suspension behavior Turn adjusting screws clockwise all the way e Info djusting screws are located at the top end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline Compression damping Standard 10 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 11 TUNING THE CHASSIS 42 11 13 Adjusting the rebound damping of the fork e Info The hydraulic rebound damping determines the fork suspension behavior Remove protection caps
46. 18 0 super unleaded ROZ 95 RON 95 PON approx 4 76 US gal 91 p 124 Total fuel 33 0 Super unleaded ROZ 95 RON 95 PON capacity 8 72 US gal 91 p 124 approx Close the filler caps p 16 L02718 10 10 SERVICE SCHEDULE 35 10 1 Service schedule Every 30 operating hours Every 20 operating hours Every 10 operating hours after every race Once after 1 operating hour Check the free travel of the foot brake lever p 73 Check the frame and swingarm Check the swingarm bearing Check the heim joints at the top of the shock absorber Check the shock absorber linkage Conduct a minor fork service Check the brake discs p 69 Check the rear brake fluid level p 74 e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e Check the chain rear sprocket engine sprocket and chain guide 62 Check the chain tension p 61 O e Lubricate all moving parts e g hand lever chain and check for smooth operation e Change the engine oil and oil filter and clean the oil screens p 92 Change the absorbing elements in the outer clutch hub 4 e e e e e e Check all hoses e g fuel cooling bleeder drainage etc and sleeves for cracking leaks and incorrect rout ing Check the antifreeze and coolant level p 88 Check the cables for damage and routing without
47. 3 MA Standard Ear lier engine oils from the automobile industry were used for 4 stroke motorcycles because there was no separate motorcycle specifi cation Whereas long service intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis cosity The viscosity describes only one property of oil and says nothing about quality INDEX A ACCESSOS anane A HE dra ORC Qe ke e C E OE Ak A 8 Air filter Canine aes Psa e sch Utd aee wa TEE E 55 WSU SUNS sce ce Gi ciel ae cap Sods dese cc Gotten oe wt aie Ge Made gaa 56 KEMIOVING y ya ol ad Sew k aw Er CORE OLEO RR ae 55 Air filter box CLANS at sei icis oti mou tee S ax miu ASUS ca Se rs 55 Antifreeze CHECKINS oos DPI 88 Auxiliary substances 8 B Basic chassis setting checking with rider s weight 37 Battery uc ere eroe ae e RR e ear ak cens 84 fc Pip ARCH 85 call VIII cae 87a DEC Belo rd e e Le aed 84 Blink cod Vu yy oe Bee RENI Yu Mw mem 101 Brake discs sna Gad Nan ar leere 69 Brake fluid front brake adding
48. 4 5 4 43 C jCX 2 l X103 103 CW2 _ X103 M10 G10 BD 12 X113 BD 12 wh rd br o X110 b gt o 4 E1 N FC 2 or or 6 E1 gt 2 F1 450 Rally Factory Replica 2015 24 WIRING DIAGRAM Components A11 Motor electronics control unit G10 Battery K10 Starter relay with main fuse M10 Starter motor S21 Electric starter button 109 110 24 WIRING DIAGRAM Page 2 of 8 24 2 _ E E qo 3 j 4 j 08 j a 7 A11 1 A5 6 A1 e HY 33 X10 wh bl a wh bl wh bl rd wh bl rd rd br br X9 ji DY 4 X3 X58 X90 X56 X56 X56 EB 4 FE 2 AI 2 FH 16 FH 16 FH 16 CN CN CN r N B87 F1 7 F1 6 F1 3 X102 X32 CC 12 AP 6 Er j R55 s CI 12 m X101 XZ N NZ K 2 EB 4 e FE 2 Al 2 o FH 16 z FH 16 z FH 16 lt l DY A X3 X58 X90 X56 X56 X56 X9 5 j oi c 5 gt gt 3 E1 gt r 3 E1 1 E8 b Lb 4 E5 8 b gt X103 BD 12 AD 12 X104 gt 3 F1 gt 3 E1 1 F8 lo gt gt o 3 E1 450 Rally Factory Replica 2015 d 3 C1 gt 102803 10 24 WIRING DIAGRAM Components A11 Motor electronics control unit B87 Radiator fan temperature switch F1 3 Fuse F1 6 Fuse F1 Fuse G20 Alternator K30 Power relay M60 R
49. Hand brake lever p 13 Foot brake lever p 17 NJ O on GW SN e e 9 SERIAL NUMBERS 11 Chassis number Is embossed in the steering head at the right 401945 10 Type label is fixed to the right of the steering head 402399 10 The engine number Is stamped on the left side of the engine under the engine sprocket 401949 10 The key number o9 for the steering lock is stamped onto the key connector 1 402247 10 The fork part number eb Is stamped on the inner side of the fork stub 401947 10 9 SERIAL NUMBERS 12 Shock absorber article number is located on the bottom of the shock absorber com pensating tank 401948 10 6 CONTROLS 13 6 1 Clutch lever The clutch lever Is fitted the left side of the handlebar The clutch is hydraulically operated and self adjusting 6 2 Hand brake lever The hand brake lever Is fitted on the right side of the handlebar The hand brake lever operates the front brake The throttle grip Is fitted on the right side of the handlebar The kill switch is fitted on the left side of the handlebar Possible states e Kill switch amp in basic position In this position the ignition circuit is closed and the engine can be started e Kill switch amp pressed In this position the ignition circuit is interrupted a run ning engine stops and a non running engine will not start The light switch
50. OOTING 99 fais Pose Aton The engine does not turn when the Operating error Carry out the start procedure p 31 electric starter button is pressed The battery is discharged Recharge the battery p 85 Check the charging voltage Check the open circuit current Check the stator winding of the alternator Main fuse blown Change the main fuse p 85 Starter relay defective Check the starter relay Starter motor defective Check the starter motor Operating error Carry out the start procedure p 31 The coupling of the fuel hose connec Join the fuel hose connection tion is not connected Fuse 8 is blown Change the fuses of individual power consumers p 86 The engine turns but does not start Idle speed is not set correctly Adjust the idle speed p 91 Spark plug oily or wet Clean and dry the spark plug or change it if necessary Electrode distance plug gap of spark plug too wide Adjust the plug gap Guideline Spark plug electrode gap 0 9 mm 0 035 in Faulty ignition system Check the ignition system Short circuit cable in wiring harness Check the wiring harness visual check frayed kill switch defective Check the electrical system Defect in the fuel injection system Read out the fault memory using the KTM diag nostics tool Engine does not speed up Defect in the fuel injection system
51. OWNER S MANUAL 2015 450 Rally Factory Replica Art no 3213181en DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle You are now the owner of a state of the art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly We wish you a lot of enjoyment in riding this vehicle Enter the serial numbers of your vehicle below Chassis number p 11 Dealer s stamp Engine number p 11 Key number p 11 The Owner s Manual contained the latest information for this model series at the time of going to print Slight deviations resulting from continuing development and design of the motorcycles can however not be completely excluded All specifications are non binding KTM Motorrad AG 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 illustrations and descriptions misprints and other errors The models portrayed partly contain special equipment that does not belong to the regular scope of supply 2014 KTM Sportmotorcycle GmbH Mattighofen Austria All rights reserved Reproduction even in part as well as copying of all kinds is permitt
52. RVICE WORK ON THE CHASSIS 54 12 14 Dismounting the front fender Remove cable tie s Remove screws Remove front fender 9 12 15 Installing the front fender Position front fender Q Mount and tighten screws Guideline IO Nm 7 GR Secure cable tie s L02787 11 Pull on loop Q At the same time lift the seat at the rear and take it off 12 SERVICE WORK ON THE CHASSIS 55 1247 Mounting the seat Position the seat between the two front fuel tanks Insert locking into the lock housing and push down the rear of the seat until the locking pin engages with a click Check that the seat is correctly mounted Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to increased wear Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Preparatory work Remove the seat p 54 Main work Remove screws Remove air filter w 02744 10 Warning Environmental hazard Hazardous substances cause environmental damage Dil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations
53. Remove the main silencer p 56 Main work Remove screws 1 5 imm lt L02828 10 Carefully lower fuel tank 4 Remove screw Remove fitting Press linkage lever 9 downward Press angle lever Qo toward the rear L02823 10 12 SERVICE WORK ON THE CHASSIS 52 Place an object under the rear wheel to lift the swingarm L02824 01 Remove screws Remove screw 02827 10 Remove the shock absorber toward the top L02826 01 12 13 Installing the shock absorber A Main work Carefully position the shock absorber into the vehicle from above LO2826 01 Mount and tighten screw Guideline Screw connection shock M10 45 Nm Loctite 243 absorber top 33 2 Ibf ft L02827 11 12 SERVICE WORK ON THE CHASSIS 53 Mount and tighten screws Remove the object under the rear wheel Mount and tighten screw cap Guideline Nut linkage lever to angle lever M14x1 5 100 Nm 73 8 Ibf ft Mount and tighten screw Guideline Screw connection shock M10 45 Nm Loctite 243 absorber bottom 33 2 Ibf ft Raise fuel tank Q Mount and tighten screws Q Guideline Remaining screws chassis M8 25 Nm 18 4 Ibf ft SS w Finishing work Install the main silencer p 56 Mount the seat p 55 Remove the motorcycle from the lift stand 44 12 SE
54. TET Repeatedly press the button briefly until Km h Mph flashes Km h Mhz 000 LAP CLK H Setting the Km h Press the button Setting the Mph 400329 01 Press the button Wait 3 5 seconds Z settings are stored Info If no button is actuated for 10 12 seconds or there is no signal from the wheel speed sensor then the settings are automatically stored and the Setup menu is closed 7 SPEEDOMETER 1 4 Setting the speedometer functions e Info When the vehicle is delivered only the SPEED H and SPEED ODO display modes are activated Condition The motorcycle is stationary stored Repeatedly press the button briefly until H appears at the bottom right of the display Press the button for 2 3 seconds Mc M M St 2 Z Setup menu is displayed and the active functions are shown ANS e Info Km h Mph 000 LAP CLK H If no button is pressed for 10 12 seconds the settings are automatically If no button is pressed for 20 seconds or if no impulse comes from the 400318 01 wheel speed sensor the settings are automatically saved and the setup menu is closed Repeatedly press the button briefly until the desired function flashes he selected function flashes Activating the function Press the button Z symbol continues to appear in the display and the next function appears Deactivating a function Press
55. Turn adjusting screw clockwise up to the last perceptible click Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping standard 18 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce damp Ing 11 6 Measuring the unloaded rear wheel sag Preparatory work Raise the motorcycle with the lift stand p 44 11 TUNING THE CHASSIS 39 400988 10 Main work Measure the vertical distance between the rear axle and a fixed point such as a marking on the side cover Note down the value as dimension Q Finishing work Remove the motorcycle from the lift stand p 44 11 7 Checking the static sag of the shock absorber 400989 10 Condition The fuel tanks are half full Measure distance of rear wheel unloaded p 38 Hold the motorcycle upright with the aid of an assistant Measure the distance between the rear axle and the fixed point again Note down the value as dimension e Info The static sag is the difference between measurements ana Check the static sag Static sag 35 mm 1 38 in Ifthe static sag is less or more than the specified value Adjust the spring preload of the shock absorber 40 11 8 Checking the riding sag of the shock absorber S gt NS O Condition The fuel tanks are half full Meas
56. adiator fan T20 Voltage regulator 111 112 24 WIRING DIAGRAM Page 3 of 8 24 3 hi 4 B1 lo 4 B1 p 1 4 1 d 4 B1 gt f 4 1 D gt 0 4 1 SS x x h aO r yor 1 1 mmm gn or 2 2 gn or gn ye gn ye PpI4 B1 12 88 4 gt e d S 5 5 B a b lt in 5 X48 X47 X51 X108 X56 AH 2 AH 2 FL 1 FO 2 FH 16 f CN 101 2 2 X103 P53 P57 CI 12 F1 1 B86 B85 IBD 12 CEN CC 12 o AD 12 X102 X104 4 4 2 AK 2 FL 1 NIFO 2 FH 16 X44 X108 X56 I AH 2 AH 2 X48 X47 a P p g amp g 2 1 08 a gt wh gr 2 E8 r gt ye bu 2 E8 f gt 2 F8 lo gt 2 F8 lo gt e D gt 0 4 1 2 E8 r o ye bu 4 E1 450 Rally Factory Replica 2015 F9 4 F1 gt L02804 10 24 WIRING DIAGRAM Components B85 Front brake light switch B86 Rear brake light switch F60 License plate lamp FI Fuse P53 Horn P55 Brake tail light P57 High beam S58 Light switch horn button kill switch 113 114 24 WIRING DIAGRAM Page 4 of 8 24 4 E 3 C8 d d 6 B1 3 B8 lo 3 B8 hi 3 B8 p o E T 00 7 Y lo 5 B1 2
57. an authorized KTM workshop First gear is used for starting off or for steep inclines When conditions allow incline road situation etc you can shift into a higher gear To do so release the throttle while simulta neously pulling the clutch lever shift into the next gear release the clutch and open the throttle 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 Always open the throttle only as much as the engine can handle abrupt throttle opening increases fuel consumption 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 open the throttle or shift again Switch off the engine if you expect to be standing for a long time Guideline 22min Avoid frequent and longer slipping of the clutch This heats the engine oil the engine and the cooling system Ride with a lower engine speed instead of with a high engine speed and a slipping clutch 9 5 Braking Warning Danger of accidents If you brake too hard the wheels can lock Adapt your braking to the traffic situation and the road conditions Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake Check the brake system and do not cont
58. an ensure that problems and conflicts do not occur To protect the future of the motorcy cle 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 9 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 maintain your motorcycle Only then will you find out how to cus tomize 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 should be handed over to the new owner if the vehicle is sold 3 IMPORTANT NOTES 8 3 Guarantee warranty The work prescribed in the service schedule must be carried out by an authorized KTM work
59. ar for damage wear and looseness Ifa rubber grip is damaged worn or loose Change and secure the rubber grip Grip adhesive 00062030051 p 125 401197 01 12 37 Additionally securing the rubber grip Preparatory work Check the rubber grip p 65 Main work Secure the rubber grip at two points using the securing wire securing wire 54812016000 Wire twister forceps U6907854 Z twisted wire ends face away from the hands and are bent toward the rub ber grip 401198 01 12 38 Adjusting the basic position of the clutch lever Adjust the basic setting of the clutch lever to your hand size by turning adjusting Screw Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 12 39 Checking correcting the fluid level of the hydraulic clutch e Info The fluid level rises with increased wear of the clutch lining discs Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover o with membrane Check the fluid level Fluid level under top level of container 4 mm 0 16 in gt If the flui
60. ar sprocket carrier and the rear hub will be damaged Preparatory work Raise the motorcycle with the lift stand p 44 Remove the rear wheel p 79 Main work Check bearing Q gt Ifthe bearing is damaged or worn Change the bearing Check rubber dampers o of the rear hub for damage and wear If the rubber dampers of the rear hub are damaged or worn Change all rubber dampers in the rear hub Lay the rear wheel on a workbench with the rear sprocket facing upward and insert the wheel spindle in the hub To check the play O hold the rear wheel tight and try to rotate the rear sprocket e Info Measure the play on the outside of the rear sprocket Play in rubber dampers rear wheel lt 5 mm s 0 2 in f play O is larger than the specified value Change all rubber dampers in the rear hub Finishing work Install the rear wheel p 80 Remove the motorcycle from the lift stand p 44 14 6 Checking the tire condition Info Only mount tires approved and or recommended by KTM Other tires could have a negative effect on riding behavior The type condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle The tires mounted on the front and rear wheels must have a similar profile Worn tires have a negative effect on riding behavior especially on wet surfaces Examine the front and rear tires
61. camp M8 j Screw license plate holder tp me 20Nm A8I Eu rr od rear fuel tank top 25 Nm 18 4 Ibf ft Loctite 243 Ser steering stem tem e Senmisan fla TT EEE mana 0 Screw connection engine mounting M10 45 Nm 33 2 Ibf ft Loctite 243 bracket Screw connection shock absorber bot 45 Nm 33 2 Ibf ft Loctite 243TM tom Screw engine bearer on frane _ Mi 21 ri0 F o aibi Mod Nu turn sial woas _ OoOO O _ angle lever on swingarm Miis iONmUSSI O _ Screw top steering head MOd I2NmSER Screw front wheel spindle waas 4p Nm 29 5 br TT Nut rear wheel spindle MBS jT TT _ 108 Page 1 of 8 24 1 24 WIRING DIAGRAM Pe ee i es _ X 8 ro N e 00 CN A11 9 2 A2 A c C 30 7 HY 33 HY 33 s HY 33 X10 X10 X10 6 22 33 br br br pu wh wh gr b bl wh rd wh rd bl bl wh rd wh rd br pu br br pu br bu rd bu rd bl bl br br br pu or or W W W wh gr N X301 lt l AD 12 X104 el AD 12 X104 ERE AF 4 wh gr wh gr gt 3 E1 Lo mil 5 B1 gt or 5 B1 Lb 2 E1 bu rd wh rd bu rd br br br br pu or or wh wh wh rd wh rd br pu br bu rd bu rd X300
62. controls Adjust the basic position of the clutch lever p 65 Adjust the free travel of the hand brake lever p 69 Adjust the free travel of the foot brake lever p 74 Adjust the basic position of the shift lever p 91 Get used to handling the motorcycle on a suitable piece of land before making a longer trip e Info Offroad you should be accompanied by another person on another machine so that you can help each other Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle Do not make any offroad trips that over stress your ability and experience Hold the handlebar firmly with both hands and keep your feet on the footrests when riding If you carry any baggage make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis tribution between the front and rear wheels 8 PREPARING FOR USE 30 e Info Motorcycles react sensitively to any changes of weight distribution Do not exceed the overall maximum permitted weight and the axle loads Guideline Maximum permissible overall weight 400 kg 882 Ib Maximum permissible front axle load 190 kg 419 Ib Maximum permissible rear axle load 250 kg 551 Ib Run inthe engine p 30 8 2 Running in the engine During the running in phase do not exceed the specified engine speed and engine performance Guideline Maximum engine speed Durin
63. cordingly Small weight differences can be compensated by adjusting the spring preload but in the case of large weight differences the springs must be replaced 401030 01 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 setting for example has an effect on the landing after a jump the rear wheel suspension compresses more quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses more slowly These two ranges can be adjusted separately although the transition between high speed and low speed is gradual Thus changes 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 Danger of accidents Disassembly of pressurized parts can lead to injury shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help e Info The low speed setting can be seen during the slow to normal compression of the shock absorber Preparatory work Remove the seat p 54 Main work Turn adjusting screw clockwise up to the last perc
64. d level does not meet specifications Correct the fluid level of the hydraulic clutch Brake fluid DOT 4 DOT 5 1 p 124 Position the cover with the membrane Mount and tighten the screws e Info Clean up overflowed or spilled brake fluid immediately with water 12 SERVICE WORK ON THE CHASSIS 66 12 40 Changing the hydraulic clutch fluid Warning Environmental hazard Hazardous substances cause environmental damage Dil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations 12 41 Removing the trim 8102763 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws Q Remove cover with membrane Fill bleeding syringe o with the appropriate fluid Bleed syringe 50329050000 Brake fluid DOT 4 DOT 5 1 p 124 On the slave cylinder remove bleeder screw and mount bleeding syringe Inject the liquid into the system until it escapes from openings O of the master cylinder without bubbles To prevent overflow drain the fluid occasionally from the master cylinder reservoir Remove the bleeding syringe Mount and tighten the bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level under top level of container 4 mm 0 16 in Position the cover with the membrane Mount and tighten the screws Disconnect plug in connectors 1 of the turn signal
65. dly 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 nn na 20 LILO Loe I I If the lap time continues running after the button is pressed 9 memory loca LAP tions are occupied Lap 10 must be timed using the button Press the button The stop watch and the lap time are reset for 2 3 seconds Briefly press the Next display mode button Press the button Stops the clock for 2 3 seconds Briefly press the Starts the stop watch or stop the current lap time measure button ment stores it and the stop watch starts the next lap Condition e The motorcycle is stationary Repeatedly press the button briefly until LAP appears at the bottom right of the 400320 01 1 14 Viewing the lap time display 2 Briefly press the button I LILI LICI 22 LIP ress the button The stop watch and the lap time are reset for 2 3 seconds Briefly press the Select a lap from 1 10 button 400321 01 Press the button No function for 2 3 seconds Briefly press the View the next lap time button 7 SPEEDOMETER 25 7 15 Display mode SPEED ODO odometer 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 ress the button
66. dly press the button briefly until TR2 appears at the top right of the dis play 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 400324 01 7 SPEEDOMETER 26 Info The TR2 value can also be corrected manually during the journey with the but ton and the button If 999 9 is exceeded the value of TR2 is automatically reset to O O Press the button Increases value of TR2 for 2 3 seconds Briefly press the Increases value of TR2 button Press the button Reduces value of TR2 for 2 3 seconds Briefly press the Reduces value of TR2 button Wait 10 12 sec Saves and closes the Setup menu onds 7 19 Display mode SPEED A1 average speed 1 Repeatedly press the button briefly until A1 appears at the top right of the dis play 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 ress the button Displays of TR1 A1 and S1 are reset to O O for 2 3 seconds Briefly press the Next display mode button 400325 01 Press the button No function for 2 3 seconds Briefly press the No function button 7 20 Displa
67. e ade 40 Rubber grip BO KITE n wy Wan eeu Ud ed AAD ea baci 65 SEGUI EIE s Beats Sree gee E de RE AA OR dj Sn N S W 65 S Safe operation Seat POUNCE space Y DD EH x E oh S ay has 55 ME PL DK EA a pu wa KOD TE 54 SOI ICO TTE Re 8 Service schedule 35 36 NDA P TC TM 17 basic position adjusting 91 basic position checking 91 Shock absorber compression damping general 37 TREES a TOT 52 E 51 riding sag checking 39 Spring preload adjusting 40 Static Sag CHECKING fag whe 39 Side stand uu ic Pn o ow SER 18 SDare panis a sa dee SC Ue dw Red ace ss SEK deeds 8 Speedometer QOJI St O stars Yalan a Seu dk kirya NP nde d alan dn e f 2 kilometers or miles setting 20 s ting the Clock deiri Ru e Sow RUE S 21 Speedometer overview 20 Spoke tension Check IB ys n wae tect cao k ayy dek n Sen a od a 82 Stan c israel eS oet a d Steering e nn y RP Aa LO es of p 18 Ido KI lg i adest a HHHH ears HE 19 Steering head bearing qel uq ee eS a E vea aso 51 Steering head bearing play QUIS rl d aut eara
68. e instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system 6 CONTROLS m _ 027111 Turn filler caps o and e counterclockwise and lift off Mount filler caps o and and turn clockwise until the fuel tanks tightly closed e Info Route fuel tank breather hoses o without kinks 6 CONTROLS 17 4 qa Idle speed adjusting screw is located at the top left of the throttle valve body The idle speed adjusting screw is only easily accessible when the left fuel tank is removed The idle speed adjusting screw has two functions Turning it controls the idle speed Pulling it out all the way raises the idle speed during a cold start Possible states e RPM increase activated Idle speed adjusting screw is pulled out all the way e RPM increase deactivated Idle s
69. e motorcycle against falling over 401942 01 12 2 Removing the motorcycle from the lift stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press the side stand with your foot to the ground and lean the motorcycle on it e Info I When you are riding the side stand must be folded up and secured with the XS rubber band 401943 10 12 3 Bleeding the fork legs Preparatory work Raise the motorcycle with the lift stand p 44 Main work Release bleeder screws Q X excess pressure escapes from the interior of the fork ighten the bleeder screws 764 0 01 Y ur E 1 o z 1102728 10 Finishing work Remove the motorcycle from the lift stand p 44 12 SERVICE WORK ON THE CHASSIS 45 12 4 12 5 Cleaning the dust boots of the fork legs Removing the fork legs Preparatory work Raise the motorcycle with the lift stand p 44 Dismount the front fender p 54 Main work Push dust boots of both fork legs downward 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 accid
70. e motorcycle is stationary Repeatedly press the button briefly until H appears at the bottom right of the TR TR M 2 St 2 display Press the button for 2 3 seconds Km h Mph 000 LAP CLK H The Setup menu displays the active functions e Info Repeatedly press the button briefly until the desired function is opened BUDE If no button is pressed for 20 seconds the settings are automatically stored 7 SPEEDOMETER 23 Briefly press the Activates the flashing display and changes to the next display button Press the button No function for 2 3 seconds Briefly press the Deactivates the flashing display and changes to the next dis button play Press the button No function for 2 3 seconds Wait 3 5 seconds Changes to the next display without changes Wait 10 12 sec Setup menu starts stores the settings and changes to H or onds ODO 7 10 Setting the unit of measurement Condition e he motorcycle is stationary Repeatedly press the button briefly until H appears at the bottom right of the display T TR2 M A2 192 Press the button for 2 3 seconds SIM T 000 LAP CLK H Repeatedly press the button briefly until Km h Mph flashes Zi In measurement unit mode you can change the unit of measurement e Info If no button is pressed for 5 seconds the settings are automatically stored Briefly press the Starts selection activates Km h display bu
71. e oil filter cover with the O ring Pull oil filter O out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing area 18 SERVICE WORK ON THE ENGINE 94 Lubricate the O ring of the oil filter cover and mount it with the oil filter cover Q Mount and tighten screws Q9 Guideline Screw oil filter cover 6 Nm 4 4 Ibf ft LO2815 10 Remove oil filler plug with the O ring from the upper oil filter cover Fill oil filter housing at opening 9 with oil and wait until air bubbles stop rising Engine oil Total fill 1 401 1 48 qt Engine oil SAE 10W 50 p 124 ing level oil change Total filling 1 80 1 9 qt Engine oil SAE 10W 50 p 124 level engine service with oil radiator Mount and tighten filler plug Q9 L02818 10 Remove the oil filler plug with the O ring from the clutch cover fill up with engine oil Engine oil Total fill 1 40 I 1 48 qt Engine oil SAE 10W 50 p 124 ing level oil change Total filling 1 80 1 9 qt Engine oil SAE 1OW 50 p 124 level engine service with oil radiator L02820 10 18 SERVICE WORK ON THE ENGINE 95 e Info Too little engine oil or poor quality engine oil results in premature wear of the engine Install and tighten the oil filler plug with O ring Danger Danger of poisoning Exhaust gases are
72. e the motorcycle from the lift stand p 44 Pull the front brake and compress the fork powerfully a few times Z fork legs straighten Tighten screws o and Q9 Guideline Screw fork stub M8 15 Nm 11 1 Ibf ft 02785 10 di Preparatory work Raise the motorcycle with the lift stand p 44 Main work Press the brake caliper by hand on to the brake disc in order to press back the brake piston e Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut Remove chain adjuster Withdraw wheel spindle e only enough to allow the rear wheel to be pushed for ward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket e Info Protect the motorcycle and its attachments against damage by covering them Holding the rear wheel withdraw wheel spindle 9 Take the rear wheel out of the swingarm e Info Do not operate the foot brake when the rear wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged Remove spacer 14 WHEELS TIRES 80 Remove the rear sprocket carrier Q9 Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Main work Check the rear hub rubber
73. eaction 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 There your motorcycle will be opti mally cared for by specially trained experts using the specialist tools required 4 x lt lt Indicates a page reference more information is provided on the specified page The typographical formats used in this document are explained below Specific name Identifies a proprietary name Name9 Identifies a protected name Brand Identifies a brand available on the open market 2 SAFETY ADVICE 6 2 1 Use definition intended use KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use The motorcycles com ply with currently valid regulations and categories of the top international motorsport organizations Info The motorcycle is authorized for public road traffic in the homologous reduced version only In the derestricted version the motorcycle must be used only on closed off properties remote from public road traffic This motorcycle is designed for use in offroad endurance competition and not primarily for use in motocross 2 2 Safety advice A number of safety instructions need to be followed to operate the vehicle safely Therefore read this manual carefully The safety instructions are highlighted in the
74. ear fuel tank approx 18 0 4 76 US gal Super unleaded ROZ 95 RON 95 PON 91 p 124 Total fuel capacity approx 33 01 8 72 US gal Super unleaded ROZ 95 RON 95 PON 91 p 124 23 4 Chassis Lattice frame of chromium molybdenum steel tubes powder coated Suspension travel Suspension travel Brake discs diameter Brake discs wear limit Tire air pressure on road Tire air pressure off road Secondary drive ratio 23 TECHNICAL DATA 105 23 5 Electrical system Lithium ion battery Battery voltage 13 2 V Nominal capacity 4 6 Ah maintenance free High beam HB3 socket P20d 12 V 60W Low beam HB3 socket P20d Parking light W5W socket W2 1x9 5d 5 W Indicator lamps W1 2W socket W2x4 6d 10 W Brake tail light LED License plate lamp W5W socket W2 1x9 5d 5 W 23 6 Tires ent res 90 90 21 54S TT 130 80 18 66S TT Michelin T63 Michelin T63 Additional information is available in the Service section under http www ktm com 23 7 Fork Fork part number 14 18 2N 40 Compression damping Standard 10 clicks Rebound damping Standard 20 clicks Spring length with preload spacer s 485 mm 19 09 in Spring rate Weight of rider soft 65 75 kg 143 165 Ib 4 6 N mm 26 3 Ib in Oil capacity fork leg without 400 ml 13 52 fl oz Fork oil SAE 4 4860116651 p 124 cartridge 23 TECHNICAL DATA 106 23 8 Shock absorber Shock abs
75. echarging the battery 4 85 15 4 Changing the main fuse 85 15 5 Changing fuses of individual power COJISUINSISu uuu ee3EPHH E DD 86 COOLING SYST E MI lt i u u xera lara man inre sias 88 16 1 Cooling system 88 16 2 Checking the antifreeze and coolant level 88 16 3 Checking the coolant 88 16 4 Draining the coolant 4 89 16 5 Refilling coolant 89 TUNING THE ENGINE ais eterna kk oC annie 90 17 1 Checking the play in the throttle cable 90 17 2 Adjusting the play in the throttle cable 90 17 3 Adjusting the idle speed 91 17 4 Checking the basic position of the shift lever 91 17 5 Adjusting the basic position of the shift gt tudin ctp ul SURE UNE 91 SERVICE WORK ON THE ENGINE 92 18 1 Checking the engine oil level 92 18 2 Changing the engine oil and oil filter cleaning the oil screens 4 92 18 3 Adding engine oil 95 CLEANING CARE 96 19 1 Cleaning the motorcycle 96 19 2 Checks and maintenance steps for winter operad
76. ed only with the express written permission of the copyright owner ISO 9001 12 100 6061 According to the international quality management standard ISO 9001 KTM uses quality assurance processes that lead to the maximum possible quality of the products Issued by T V Management Service ISO 9001 REG NO 12 100 6061 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria TABLE OF CONTENTS 1 MEANS OF REPRESENTATION 5 1 1 Symbols used 5 1 2 Formats USEC esnan l dal 5 2 SAFETY ADVICE ai 6 2 1 Use definition intended use 6 2 2 Safety advice 6 2 3 Degrees of risk and symbols 6 2 4 Tampering warning 6 2 5 safe operation 7 2 6 Protective clothing 7 2 7 7 2 8 Environment n 2 0 Owner s Manual eese 7 3 IMPORTANT NOT ES 8 SN Guarantee warranty 8 3 2 Operating and auxiliary substances 8 99 Spare parts accessories 8 3 4 DEI VICE lin 8 3 5 idR 8 3 6 Customer servIce
77. eed sensor arrives the left side of the dis play changes back to the SPEED mode 1 1 Display mode SPEED speed 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 e Info I Making the setting according to the country When an impulse comes from the front wheel the left side of the speedometer display changes to the SPEED mode and the current speed is shown 400317 02 7 8 Display mode SPEED H service hours Condition e The motorcycle is stationary Repeatedly press the button briefly until H appears at the bottom right of the display In display mode H the service hours of the engine are displayed The service hour counter stores the total traveling time e Info The service hour counter is necessary for ensuring that service work is carried 400316 01 out at the right intervals If the speedometer is in H display mode at the start of the journey it automati cally changes to the ODO display mode The H display mode is suppressed during the journey Press the button The display changes to the Setup menu of the speedometer for 2 3 seconds functions Briefly press the Next display mode button Press the button No function for 2 3 seconds Briefly press the No function button 1 9 Setup menu Condition e Th
78. efueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Note Material damage Premature clogging of the fuel filter n some countries and regions the available fuel quality and cleanliness may be sufficient This will result in problems with the fuel system Your authorized KTM workshop will be glad to help Only refuel with clean fuel that meets the specified standards Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Switch off the engine Open the filler caps p 15 Fill the fuel tank with fuel up to measurement Guideline Measurement of Measurement f j 45mm J77i 45 mm 1 77 in Fuel tank capacity 0000 tank Fuel tank capacity 0000 Fuel tank half 7 5 super unleaded ROZ 95 RON 95 PON front left 1 98 US gal 91 p 124 approx Fuel tank half 7 5 super unleaded ROZ 95 RON 95 PON front right 1 98 US gal 91 p 124 approx Rear fuel tank
79. ehicle handling due to different tire tread patterns on front and rear wheels front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Adapt your riding speed to the road conditions and your riding ability Warning Danger of accidents Accident risk caused by presence of a passenger A Your vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of accidents Failure of brake system Warning Danger of accidents Critical riding behavior due to inappropriate riding Ifthe foot brake lever is not released the brake linings drag continuously The rear brake may fail due to overheating Take your foot off the foot brake lever when you are not braking Warning Danger of accidents Unstable riding behavior gt Do not exceed the maximum permissible weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons Info When using your motorcycle remember that others may feel disturbed by excessive noise Make sure that the pre delivery inspection work has been carried out by an authorized KTM workshop Z You receive a delivery certificate and the service record at vehicle handover Before your first trip read the entire operating instructions carefully Get to know the
80. ents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray p 126 Press the dust boots back into their normal position Remove excess oil Finishing work Install the front fender p 54 Remove the motorcycle from the lift stand p 44 Preparatory work Raise the motorcycle with the lift stand p 44 Remove the front wheel p 78 Dismount the front fender p 54 Remove the trim p 66 Main work Remove screws with washers Allow the brake caliper and brake line to hang tension free to the side Remove cable binder Loosen screws 9 Take out the left fork leg Loosen screws Take out the right fork leg 12 SERVICE WORK ON THE CHASSIS 46 12 6 Installing the fork legs A Main work Position the fork legs v Bleeder screws are positioned toward the front e Info The upper triple clamp must be flush with the upper edge of the fork legs Tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 Ibf ft Tighten screws Guideline Screw bottom triple clamp 12 Nm 8 9 Ibf ft Secure the brake line with cable binder Position the brake caliper Mount and tighten screws w
81. eptible click Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Compression damping low speed standard 12 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce damp Ing 11 TUNING THE CHASSIS 38 Finishing work Mount the seat p 55 11 4 Adjusting the high speed compression damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury he shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help e Info The high speed setting can be seen during the fast compression of the shock absorber Preparatory work Remove the seat p 54 Main work Turn adjusting screw clockwise all the way Turn back counterclockwise by the number of turns corresponding to the shock absorber type Guideline Compression damping high speed standard 34 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce damp Ing Finishing work Mount the seat p 55 11 5 Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury he shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help
82. er sensor A D type input signal too high 33 H warning lamp MIL flashes 3x long 3x short Error level condition Injector cylinder 1 circuit fault Blink code of Fl warning lamp MIL 37 Fl warning lamp MIL flashes 3x long 7x short Error level condition Ignition coil 1 cylinder 1 circuit fault Blink code of Fl warning lamp MIL Error level condition 41 FI warning lamp MIL flashes 4x long 1x short Fuel pump relay short circuit to ground or open circuit Open short circuit to plus 23 TECHNICAL DATA 102 23 1 Motor Valve clearance Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Transmission ratio 2422 588 bth gear 24 24 Sixth gear 21 18 Alternator 12 V 200 W tion adjustment 23 2 Motor tightening torques wis Toq ememr Screw clutch springretainer o Screw oll ilter cover e 1 8NnUABHU O O 23 TECHNICAL DATA 103 Screw alternator cover alternator Screw alternator cover M6 J10 Nm 10 N m 7 4 Ibf ft 4 bf ft Screw bearing bolt for starter idler o 10 Nm 7 4 Ibf ft ed 243 gear eme omaha E We Lown brs _ Er Wem ra Screw cyinderhead M6 TJ _ Sorem engine case m o y O Screw pressure pump cover we ioie 7 Screw shift arum locatis M6 10 ioie _ Sorem siter ___ TT 6 aos
83. eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents Reduced braking efficiency due to use of non approved brake linings Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construc tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings If brake linings are used that differ from the originals there is no guarantee that they comply with the origi nal license The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and
84. fuel tank toward the front Remove the engine guard p 68 Remove the front right fuel tank p 58 Check the throttle cable routing p 64 Main work Move the handlebar to the straight ahead position Push back sleeves Q Loosen nut Turn adjusting screw e in as far as possible Loosen nut Turn adjusting screw so that there is play in the throttle cable at the throttle grip Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Tighten nut Press and hold the throttle grip in the closed setting Turn out adjusting screw until there is no play in the upper throttle cable ighten nut Push sleeves on Check the throttle grip for smooth operation Finishing work Install the fuel tank at the front Mount the seat p 55 Mount the trim p 67 Check the play in the throttle cable p 90 17 TUNING THE ENGINE 91 Run the engine warm and push the idle speed adjusting screw all the way in Set the desired idle speed by turning the idle speed adjusting screw Guideline Idle speed 2 000 2 200 rpm e Info Turn counterclockwise to increase the idle speed Turn clockwise to decrease the idle speed LO2716 10 Siton the vehicle in the riding position and determine distance O between the upper edge of your boot and the shift lever Distance between shift lever and upper 10 20 mm 0
85. g efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Dil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info The service life of the chain depends largely on its maintenance Preparatory work Raise the motorcycle with the lift stand p 44 12 SERVICE WORK ON THE CHASSIS 61 Main work Clean the chain regularly and then treat with chain spray Chain cleaner p 125 Off road chain spray p 125 400725 01 Finishing work Remove the motorcycle from the lift stand p 44 12 30 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain is too taut the components of the secondary power transmission chain engine sprocket rear sprocket bear ings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme cases If the chain is too loose however it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine Ensure that the chain tension is correct and adjust it if necessary Preparatory work Raise the motorcycle with the lift
86. g the first operating hour 7 000 rpm Maximum engine performance Avoid fully opening the throttle 9 RIDING INSTRUCTIONS 31 9 1 Checks and maintenance when preparing for use e 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 used Check the engine oil level p 92 Check the electrical system Check the front brake fluid level p 70 Check the rear brake fluid level p 74 Check the front brake linings p 71 Check the rear brake linings p 75 Check that the brake system is functioning properly Check the coolant level p 88 Check the chain for dirt accumulation p 60 Check the chain rear sprocket engine sprocket and chain guide p 62 Check the chain tension p 61 Check the tire condition p 81 Check the tire air pressure p 82 Check the spoke tension p 82 Clean the dust boots of the fork legs p 45 Bleed the fork legs p 44 Check the air filter Check the fuel 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 reserves 9 2 Starting Danger A Danger of poisoning Exhaust gases are toxic and inhaling them may result in
87. he value value value value next value SETUP menu Display mode SPEED CLK time 7 SPEEDOMETER 28 Display Press the but Briefly press the Press the but Briefly press the Wait 3 5 sec Wait 10 12 sec ton for 2 3 button ton for 2 3 button onds onds seconds seconds Display mode The stop watch Next display Stops the clock Starts the stop SPEED LAP lap and the lap time mode watch or stop time are reset the current lap time measure ment stores it and the stop watch starts the next lap Viewing the lap The stop watch Select a lap No function View the next time and the lap time from 1 10 lap time are reset Display mode No function Next display No function No function SPEED ODO mode odometer Display mode Displays of TR1 Next display No function No function SPEED TR1 trip A1 and S1 are mode master 1 reset to O O Display mode Clears the val Next display Reduces value Reduces value SPEED TR2 trip ues TR2 and A2 mode of TR2 of TR2 master 2 Setting TR2 trip Increases value Increases value Reduces value Reduces value Saves and master 2 of TR2 of TR2 of TR2 of TR2 closes the Setup menu Display mode Displays of TR1 Next display No function No function SPEED A1 average A1 and S1 are mode speed 1 reset to O O Display mode No function Next display No function No function SPEED A2 average mode speed 2 Display mode Displays of TR1 Next dis
88. he low speed compression damping of the shock absorber 37 11 4 Adjusting the high speed compression damping of the shock absorber 38 11 5 Adjusting the rebound damping of the shock SOF oe keza nn 38 11 6 Measuring the unloaded rear wheel sag 38 11 Checking the static sag of the shock absorber 39 11 8 Checking the riding sag of the shock absorber 39 11 9 Adjusting the spring preload of the shock absorber Wu uU uu u u u u u uuu s 40 11 10 Adjusting the riding Sag 40 11 11 Checking the basic setting of the fork 4 11 12 Adjusting the compression damping of the qc 41 11 13 Adjusting the rebound damping of the fork 42 11 14 Handlebar position 42 11 15 Adjusting the handlebar position 42 SERVICE WORK ON THE CHASSIS 44 12 1 Raising the motorcycle with the lift stand 44 12 2 Removing the motorcycle from the lift stand 44 12 3 Bleeding the fork legs 44 12 4 Cleaning the dust boots of the fork legs 45 12 5 Removing the fork legs 4 45 12 6 Installing the fork legs 4 46 12 7 Removing the lower triple clamp 46 12 8 Installing the lowe
89. he thermostat Defect in radiator fan system Check fuse 7 Check the radiator fan 21 TROUBLESHOOTING i Tu Tam TT TT TT TT FI warning lamp MIL lights Defect in the fuel injection system Stop the motorcycle and identify the faulty part up flashes using the blink code e Info See blink code Check the cabling for damage and the electri cal plug in connections for corrosion and dam age Read out the fault memory using the KTM diag nostics tool High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary The engine oil level is too high Check the engine oil level p 92 The engine oil is too thin low viscos Change the engine oil and oil filter and clean ity the oil screens p 92 Piston and cylinder worn Measure the piston cylinder mounting clear ance The battery is discharged The battery is not being charged by Check the charging voltage the alternator Check the stator winding of the alternator Unwanted power consumer Check the open circuit current Speedometer values deleted time The battery in the speedometer is Change the speedometer battery stop watch lap times discharged The high beam low beam parking Fuse 3 is blown Change the fuses of individual power light tail light license plate lamp consumers p 86 speedometer and horn are not work Ing Brake light and turn
90. hells Q Remove the clamp bar with the rubber cones Remove the two screws D Take off the handlebar supports Place the handlebar supports in the required position Mount and tighten the two Screws Guideline Screw handlebar support MIO 40 Nm Loctite 243 29 5 Ibf ft Condition Spacer 9 fitted Usea M10x35 screw Condition without a spacer Use a M10x25 screw e Info Position the left and right handlebar supports evenly Fit the rubber cones 7 and clamp bar Q9 Fit the lower shells Q Position the handlebar e Info Make sure cables and wiring are positioned correctly Position the handlebar clamps e with rubber washers o and elastomers Elastomer kit green soft quality SXS05125203 Elastomer kit yellow medium quality standard 5X805125204 Elastomer kit red hard quality SXS05125205 e info The elastomers are available in different versions Position bracket Mount and evenly tighten the four screws Guideline Screw handlebar clamp M8 16 Nm 11 8 Ibf ft e Info Make sure the gap width is even 12 SERVICE WORK ON THE CHASSIS 4A 12 1 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Raise the motorcycle at the frame underneath the engine Lift stand 78929955100 Z wheels must no longer touch the ground Secure th
91. hift 17 6 16 Foot brake 17 OAL o cin cR 18 Ds Steering TOCK i aa ax dk ben ua lan kak axi kaka k 18 6 19 Locking the steering 18 6 20 Unlocking the steering 19 T SPEEDOMETER TOC 20 7 1 Speedometer overview 20 Activation and 20 7 3 Kilometers or miles setting 20 7 4 Setting the speedometer functions 21 7 5 Setting the clock 21 7 6 Viewing the lap time 21 7 7 Display mode SPEED 22 7 8 Display mode SPEED H service hours 22 7 9 SOLD NN DD DED EEE eba gp mg mo 22 10 11 12 2 7 10 Setting the unit of measurement 23 7 11 Display mode SPEED CLK time 23 7 12 Setting the clock 24 7 13 Display mode SPEED LAP lap time 24 7 14 Viewing the lap time 24 7 15 Display mode SPEED ODO odometer 25 7 16 Display mode SPEED TR1 trip master 1 25 7 17 Display mode SPEED TR2 trip master 2 25 7 18 Setting TR2 trip maste
92. hould be done after the parts are cooled down and while they are installed After riding on salted roads thoroughly wash the motorcycle with cold water and dry it well 401060 01 reat the engine swingarm and all other bright and zinc plated parts except for the brake discs with a wax based corrosion inhibitor e Info Corrosion inhibitor is not permitted to come in contact with the brake discs as this would greatly reduce the braking force Clean the chain p 60 20 20 1 20 2 STORAGE 98 Storage Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Info If you want to garage the motorcycle for a longer period take the following actions Before storing the motorcycle check all parts for function and wear If service repairs or replacements are necessary you should do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season Add fuel additive the la
93. id level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Dil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid is corrosive Use only clean brake fluid from a sealed container Stand the vehicle upright Remove screw cap with the washer and membrane Add brake fluid to the MAX level Brake fluid DOT 4 DOT 5 1 p 124 Mount the screw cap with the washer and membrane e Inf
94. in connection of the fuel line thoroughly with compressed air e Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Lubricate the O ring and connect plug in connection of the fuel line Finishing work Install the engine guard p 68 Mount the trim p 67 Mount the seat p 55 12 SERVICE WORK ON THE CHASSIS 60 12 27 Installing the front right fuel tank Position the fuel tank Mount and tighten screws Q Guideline Screw front fuel tank 8 Nm 5 9 Ibf ft Mount fuel tank breather hose Remove the wash cap set Clean the plug in connection of the fuel line thoroughly with compressed air e Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Lubricate the O ring and connect plug in connection of the fuel line LO2746 12 Finishing work Install the engine guard p 68 Mount the trim p 67 Mount the seat p 55 12 28 Checking the chain for dirt accumulation Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 60 400678 01 12 29 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced brakin
95. ings Q Remove screw o and take off the main silencer Mount the main silencer Mount screw but do not tighten yet Attach springs Spring hooks 50305017000 Tighten screw Q Guideline IO Na 7 4 Tb f 12 SERVICE WORK ON THE CHASSIS 57 12 23 Changing the glass fiber yarn filling of the main silencer 1 Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down Do not touch hot components Info Over a period the fibers of the insulating material vanish into the air and the silencer burns out Not only is the noise level higher the performance characteristic changes Preparatory work Remove the main silencer p 56 Main work Drill out all rivets on the main silencer and remove the steel bands Carefully ham mer the rivets Inward Remove silencer cap and external tube Pull the glass fiber yarn filling from inner tube Clean the parts that need to be reinstalled and check for damage Wind adhesive tape around the end of inner tube Mount new glass fiber yarn on inner tube 401201 10 Remove adhesive tape from inner tube Slide outer tube over the glass fiber yarn Insert silencer cap into the outer tube Position the steel bands and mount the rivets Finishing work Install the main silencer p 56 12 24 Removing the fr
96. inue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a dirty or wet brake system by riding and braking gently sandy wet or slippery surfaces use the rear brake Braking should always be completed before you go into a bend Change down to a lower gear appropriate to your road speed On long downhill stretches use the braking effect of the engine To do so shift back one or two gears but do not overrev the engine You will need to apply the brakes far less often and the brake system will not overheat 9 RIDING INSTRUCTIONS 33 9 6 Stopping parking Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine Is running Secure the vehicle against use by unauthorized persons Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch hot components such as exhaust system radiator engine shock absorber and the brake system Allow these components to cool down before starting work on them Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Note Fire hazard Some vehicle components become very hot when the vehicle is operated Do not park the vehicle near flammable or explosive substances Do not place objects on
97. is fitted on the left side of the handlebar Possible states Light off Light switch is turned to the right In this position the light Is switched off 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 CONTROLS 14 6 6 Turn signal switch The turn signal switch is fitted on the left side of the handlebar Possible states P _ Turn signal off Turn signal switch is in the central position Turn signal left on Turn signal switch turned to the left Turn signal right on Turn signal switch turned to the right The horn button is fitted on the left side of the handlebar Possible states e Horn button in neutral position e Horn button pressed The horn is operated in this position The electric starter button is fitted on the right side of the handlebar Possible states e Electric starter button in basic position e Electric starter button pressed In this position the electric starter is actuated Possible states The left low fuel warning lamp lights up orange The fuel level of the two front fuel tanks has reached the reserve mark The oil pressure warning lamp lights up red The oil pressure is too low Optional warning lamp MIL lights up flashes orange The OBD has detected an emi
98. ith washers Guideline Screw front brake caliper M8 30 Nm Loctite 243 22 1 Ibf ft L02727 11 Finishing work Mount the trim p 67 Install the front fender p 54 Mount the front wheel p 78 12 7 Removing the lower triple clamp Preparatory work Raise the motorcycle with the lift stand p 44 Remove the front wheel p 78 Dismount the front fender p 54 Remove the trim p 66 Remove the fork legs p 45 Main work Remove screw Q Allow the brake caliper and brake line to hang tension free to the side 12 SERVICE WORK ON THE CHASSIS 41 Remove screws Remove the holding plate with handlebar clamps Remove screws Remove steering damper Fix handlebar onto the instrument support with cable tie s Q Secure lower triple clamp against falling out Loosen screw Q Remove screw Remove O ring D Remove protective ring and take off the seal ring beneath it Take out the lower triple clamp with the steering stem Remove the upper steering head bearing 12 8 Installing the lower triple clamp Main work Clean the bearing and sealing elements check for damage and grease High viscosity grease p 125 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing Check whether the top steering head seal
99. justing the play of the steering head bearing Preparatory work Raise the motorcycle with the lift stand p 44 Main work Remove screws Remove the holding plate with handlebar clamps Remove screws Take off steering damper Fix handlebar o onto the instrument support with cable tie s Q Loosen screws Q and Q Loosen and retighten screw Guideline Screw top steering head M20x1 12 Nm 8 9 Ibf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid strains Screw top triple clamp M8 17 Nm 12 5 Ibf ft Screw top steering stem M8 20 Nm 14 8 Ibf ft Position steering damper Mount and tighten screws Guideline Screw steering damper M6 15 Nm 11 1 Ibf ft Remove the cable tie s and place the handlebar onto the handlebar clamp base Mount the holding plate with the handlebar clamps and position the handlebar Mount and tighten screws Q Guideline Screw handlebar clamp M8 16 Nm 11 8 Ibf ft Finishing work Check the steering head bearing play p 49 Remove the motorcycle from the lift stand p 44 12 SERVICE WORK ON THE CHASSIS 51 12 1 Greaingthesteeringheadbearing Remove the lower triple clamp p 46 Install the lower triple clamp p 47 800010 10 Preparatory work Raise the motorcycle with the lift stand p 44 Remove the seat p 54
100. line Coolant level above the radiator 10 mm 0 39 in fins 1 2 1 3 qt Coolant p 124 Mount the radiator cap Take a short test ride Check the coolant level p 88 L Ez E E E RE EI LL E E EI LL Fj L02798 10 17 TUNING THE ENGINE 90 17 1 Checking the play in the throttle cable Check the throttle grip for smooth operation Move the handlebar to the straight ahead position Turn the throttle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3 5 mm 0 12 0 2 in gt If the throttle cable play does not meet specifications Adjust the play in the throttle cable p 90 Danger 400192 11 Danger of poisoning Exhaust gases are toxic inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and let it run idle Move the handlebar to and fro over the entire steering range The idle speed must not change gt If the idle speed changes Adjust the play in the throttle cable p 90 17 2 Adjusting the play in the throttle cable A Preparatory work Remove the trim p 66 Remove the seat p 54 Remove the
101. lo rna 97 TORA M 98 O L Li E ew Tnm 98 20 2 Preparing for use after storage 98 TROUBLESHOOTING 99 BEINE GODE ee 101 TECHNICAL DATA u u uu u l y k 102 25 102 23 2 Motor tightening torques 102 23 3 Capacities la kk danya la denn v kann Kaka NUS 104 23 3 1 Zug gam mm 104 ENS S MEE Vor i RE 104 ZR MEE LU Me 104 SU u Iw 104 23 5 Electrical system 105 PO ONMENI IM 105 105 23 8 Shock absorber 106 23 9 Chassis tightening torques 106 WIRING DIAGRAM cian eniin a Routard ca 108 24 1 sla ku sal k rka m dele bros EFI Orsi l ka 108 24 2 Page 2 OL m d risa 110 24 3 VASO OD Oemoer a 112 24 4 Page A of 8 memes 114 20 5 Pag IRON ucu neces Suit Una KE We cians 116 24 6 Papa 6 OF D usse kk xi Uode kr curd aus eva dA dax 118 24 7 Page 7 of Em 120 24 0 m exiis en epos eid toc pide k 122 SUB TANCE X 124 TABLE OF CONTENTS 1 MEANS OF REPRESENTATION The meaning of specific symbols is described below Indicates an expected reaction e g of a work step or a function Indicates an unexpected r
102. n Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 54 Main work Disconnect the negative minus cable of the battery Disconnect the positive plus cable o of the battery L02790 10 Remove screws 9 electronics box o in the rear area Detach rubber band at the bottom Lift the battery up and remove it Main work Place the battery in the battery holder Lithium ion battery p 105 electronics box eo in the rear area Reconnect rubber band Mount and tighten screws LO2791 11 Attach positive cable Guideline Nut cable on battery 5 Nm 3 7 Ibf ft Attach negative cable Q Guideline Nut cable on battery 5 Nm 3 7 Ibf ft Finishing work Mount the seat p 55 15 ELECTRICAL SYSTEM 85 15 3 Recharging the battery A Warning Risk of injury Batteries contain harmful substances Keep batteries out of the reach of children Keep sparks and open flames away from the battery Only charge in well ventilated rooms Maintain the minimum distance to inflammable materials Minimum clearance 1 m 3 ft Warning it Environmental hazard The battery contains elements that are harmful to the environment Do not dispose of batteries with the household waste Dispose of a defective battery in an environmentally friendly manner Give the battery to your autho
103. ne coolant temperature sensor Rollover sensor Crankshaft position sensor Manifold absolute pressure sensor Ignition coil Black Brown Blue Green Gray Light blue Orange Pink Violet Red White Yellow 123 25 SUBSTANCES 124 Brake fluid DOT 4 DOT 5 00 Standard classification DOT Guideline Use only brake fluid that complies with the specified standard see specifications on the container and that exhibits the corre Sponding properties Recommended supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Guideline Only use high quality coolant with corrosion inhibitor for aluminum motors even in countries with high temperatures Using infe rior antifreeze can result in corrosion and foaming Mixture ratio Antifreeze protection 725 45 13 anti corrosion antifreeze 49 F distilled water Recommended supplier Motorex COOLANT M3 0 Standard classification JASO T903 MA p 127 SAE p 127 SAE 10W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corre sponding properties Synthetic engine oil Recommended supplier Motorex Cross Power 4T Standard classification SAE p 127 SAE 4 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the cor
104. o Clean up overflowed or spilt brake fluid immediately with water 13 12 Checking the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help Note Danger of accidents Reduced braking efficiency caused by damaged brake discs Ifthe brake linings are not changed in time the steel brake lining carriers grind on the brake disc The braking effect is greatly reduced and the brake discs are destroyed Check the brake linings regularly Check the brake linings for minimum thickness e Minimum thickness gt 1 mm 2 0 04 in Ifthe minimum thickness is less than specified Change the rear brake linings p 76 Check the brake linings for damage and cracking f damage or cracking is visible Change the rear brake linings p 76 LO2776 10 13 BRAKE SYSTEM 76 13 13 Changing the rear brake linings Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the
105. ont left fuel tank A Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Store fuel properly in a suitable canister and keep away from children Preparatory work Remove the seat p 54 Remove the trim p 66 Remove the engine guard p 68 Main work Clean the plug in connection of the fuel line thoroughly with compressed air e Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Disconnect the plug in connection of the fuel line LO2746 10 12 SERVICE WORK ON THE CHASSIS 58 Mount wash cap set o from the separate enclosure Wash cap set 81212016100 Clean the plug in
106. orber part number 18 18 0N 40 Shock absorber WP Performance Systems Compression damping low speed Standard 12 clicks Compression damping high speed Standard 34 clicks Rebound damping Standard 18 clicks Spring preload Spring rate Riding sag 100 mm 3 94 in Fitted length 473 mm 18 62 in Shock absorber oil Shock absorber fluid SAE 2 5 5018075151 p 124 23 9 Chassis tightening torques Screw conse plate holder EXT _ Screw Ticonse piate emp EJOTFTKSOIBTZD I8NmQiIN Guest 0 2Nn 5hH Spoke nipple front wheel 5 8 8NmGT AAIIR Remaining chass M5 8NMGZIU Remaining screws chassis w samu r rn TJ I x Screw air baffle air Screw air baffle MB l Nm 1 0 7 7 lbf ft Screw brake line holder on bottom Nm 1 5 Ibf ft triple clamp Screw foot bake tever foot _ WS flottes aaam _ Seren fe tank csr ange N82 mga C fuel tap onieme 5 A Guewewlghcwer e T mo z rn o O Screw shock absorber adjusting ring M5 sm BI TT TT Tu T7 TT TT Spoke nipple rear wheel 56 744 _ Nut cable on batte y a S _ TT TT TTTTT cable on starter motor we Remaining nuts crass M Remaining screws chass M6
107. painted parts Brake fluid is corrosive Use only clean brake fluid from a sealed container Stand the vehicle upright Remove screw cap with the washer membrane Press the brake caliper by hand on to the brake disc in order to press back the brake piston Ensure that brake fluid does not overflow from the brake fluid reser voir using suction to remove it if it does e Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove cotter pin 13 BRAKE SYSTEM 3 S gt L02774 11 TI Drive out pin with drift 9 toward the rim and remove the brake linings Clean the brake caliper and brake caliper support Check that leaf spring O in the brake caliper and sliding plate in the brake caliper support are seated correctly Insert the new brake linings Q9 insert pin e and mount the cotter pin Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Add brake fluid to the MAX marking Brake fluid DOT 4 DOT 5 1 p 124 Mount the screw cap with the washer and membrane e Info Clean up overflowed or spilt brake fluid immediately with water 14 WHEELS TIRES 78 Preparatory work Raise the motorcycle with the lift stand p 44 Main work Press the brake caliper by hand on to the brake disc in order to press back the brake pistons
108. peed adjusting screw is pushed in all the way LO2716 10 The shift lever is mounted on the left side of the engine 401950 10 The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears 401950 11 Foot brake lever is located in front of the right footrest The rear brake is engaged with the foot brake lever 401956 10 6 CONTROLS 18 The side stand Q is on the left side of the vehicle 401943 10 The side stand is used to park the motorcycle e Info When you are riding the side stand e must be folded up and secured with the rubber band The steering lock o Is fitted on the left of the steering head The steering lock is used to lock the steering Steering and therefore riding is no longer possible LO2717 10 Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Park the vehicle Turn the handlebar as far as possible to the right Insert the key in the steering lock turn it to the left press it in and turn it to the right Remove the key Z Steering is no longer possible e Info Never leave the key in the steering lock 400732 01 6 6 20 CONTROLS Unlocking the steering 400731 01 Insert the key in the steering lock turn it to the left pull it out and turn it to the right Remove the key Z You can now steer
109. play No function No function SPEED S1 stop A1 and S1 are mode watch 1 reset to O O Display mode The displays of Next display No function Starts or stops SPEED S2 stop S2 and A2 are mode 2 watch 2 set to 0 0 S2 7 24 Table of conditions and menu activation Display The motorcycle is Menu can be acti stationary vated Display mode SPEED H service hours Setup menu Setting 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 A average Jo o e Display mode SPEED A2 average speed 2 Jo o e Display mode SPEED S1 stopwatch 1______________ ijiiiji r Display mode SPEED S2 stop watch 2 U III I d d 8 PREPARING FOR USE 29 8 1 Advice on first use Danger Danger of accidents Danger arising from the rider s judgement being impaired Do not operate the vehicle while under the influence of alcohol drugs and certain medications or physically or mentally impaired Warning Risk of injury Missing or poor protective clothing presents an increased safety risk Wear protective clothing helmet boots gloves pants and jacket with protectors every time you ride the vehicle Always wear protective clothing that is in good condition and meets the legal requirements Warning Danger of crashing Poor v
110. r Warning JS Environmental hazard Hazardous substances cause environmental damage Dil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations e Info Drain the engine oil only when the engine is warm Preparatory work Park the motorcycle on a level surface Remove the engine guard p 68 Main work Place a suitable container under the engine Remove oil drain plug with the magnet and seal ring Remove screw plug e with the short oil screen and the O rings x 18 SERVICE WORK ON THE ENGINE 93 X l je L02811 10 L02816 10 Remove screw plug with the long oil screen o and the O rings Completely drain the engine oil Thoroughly clean the parts and sealing surfaces Mount and tighten screw plug e with the short oil screen and the O rings Guideline Screw plug oil screen M20x1 5 15 Nm 11 1 Ibf ft Position oil screen o with the O rings on a pin wrench Position the pin wrench through the drilled hole of the screw plug in the opposite section of the engine case Push the oil screen all the way into the engine case Mount and tighten screw plug e with the O ring Guideline Screw plug oil screen M20x1 5 15 Nm 11 1 Ibf ft Mount and tighten the oil drain plug with the magnet and a new seal ring Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 Ibf ft Remove screws Q9 Take off th
111. r 2 25 7 19 Display mode SPEED A1 average speed 1 26 7 20 Display mode SPEED A2 average speed 2 26 7 21 Display mode SPEED S1 stop watch 1 27 7 22 Display mode SPEED S2 stop watch 2 27 7 23 Table offunctions 27 7 24 Table of conditions and menu activation 28 PREPARING FOR USE 29 8 1 Advice on first use 29 8 2 Running in the engine 30 RIDING 31 9 1 Checks and maintenance when preparing for u Jl DM 3l 9 3 S I O uc i aw ne prada tot Ker nel A Ke ee Wer ae b 32 9 4 SIITEITIES uuu ulula abas xa 32 9 5 n 32 9 6 STOPPING parking 33 9 7 RAISON caue uuu lll nanan pasas hande y d an net UN 33 9 8 ROC PU xm 34 SERVICE SCHEDULE j i yana u nana WEN ban kanala 35 10 1 Service schedule 35 10 2 Service work as additional order 36 TUNING THE CHASSIS 37 11 1 Checking the basic chassis setting with the rider s weight 37 11 2 Compression damping of the shock absorber 37 11 3 Adjusting t
112. r triple clamp 47 TABLE OF CONTENTS 13 14 12 9 Checking the steering head bearing play 49 12 10 Adjusting the play of the steering head n DD Dn 50 12 11 Greasing the steering head bearing 51 12 12 Removing the shock absorber 51 12 13 Installing the shock absorber 52 12 14 Dismounting the front fender 54 12 15 Installing the front fender 54 12 16 Removing the seat 54 12 17 Mounting the seat 55 12 18 Removing the air filter 55 12 19 Cleaning the air filter and air filter box 55 12 20 Installing the air filter 4 56 12 21 Removing the main silencer 56 12 22 Installing the main silencer 56 12 23 Changing the glass fiber yarn filling of the main silencer 57 12 24 Removing the front left fuel tank 5 12 25 Removing the front right fuel tank 58 12 26 Installing the front left fuel tank 59 12 27 Installing the front right fuel tank 60 12 28 Checking the chain for dirt accumulation 60 12 29 Cleaning the chaln
113. rative by any person Among those acts presumed to constitute tampering are the acts listed below Removal or puncturing of the main silencer baffles header pipes or any other components which conduct exhaust gases Removal or puncturing of parts of the intake system Lack of proper maintenance a G Replacing moving part of the vehicle or parts of the exhaust or intake system with parts other than those specified by the manu facturer 2 SAFETY ADVICE 7 2 5 Safe operation Danger A Danger of accidents Danger arising from the rider s judgement being impaired Do not operate the vehicle while under the influence of alcohol drugs and certain medications or physically or mentally impaired Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch hot components such as exhaust system radiator engine shock absorber and the brake system Allow these components to cool down before starting work on them Only operate the vehicle when it is in perfect technical condition in accordance with its intended use and in a safe and environmen tally compatible manner The vehicle
114. regularly Check the brake linings for minimum thickness e Minimum thickness gt 1 mm gt 0 04 in gt Ifthe minimum thickness is less than specified Change the front brake linings 72 Check the brake linings for damage and cracking f damage or cracking is visible Change the front brake linings p 72 13 BRAKE SYSTEM 72 13 7 Changing the front brake linings A Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning A Danger of accidents Reduced braking efficiency due to use of non approved brake linings
115. responding properties Standard classification SAE p 127 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use e Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 26 AUXILIARY SUBSTANCES 125 Recommended supplier Motorex Racing Bio Dirt Remover Recommended supplier Motorex Chain Clean Recommended supplier Motorex Fuel Stabilizer Recommended supplier KTM Motorrad AG GRIP GLUE Recommended supplier Recommended supplier Motorex Bike Grease 2000 Recommended supplier Motorex Moto Clean Recommended supplier Motorex Chainlube Offroad Recommended supplier Motorex Racing Bio Liquid Power Recommended supplier Motorex Moto Protect Recommended supplier Motorex Quick Cleaner 26 AUXILIARY SUBSTANCES 126 Recommended supplier Motorex Joker 440 Synthetic 2 STANDARDS 127 JASO T903 MA 5090I Different technical development directions required a new specification for 4 stroke motorcycles the JASO T90
116. rized KTM dealer or dispose of it at a collection point for used batteries Info Even when there is no load on the battery it discharges steadily The charging voltage of the battery must not exceed 14 4 V The charge state and the type of charge are very important for the service life of the battery If the charging current and charging voltage are exceeded the battery will be destroyed If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and will be destroyed The battery is maintenance free Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 54 Disconnect the negative cable of the battery to avoid damage to the motorcycle s electronics Main work Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 You can also use the battery charger to test the open circuit voltage and start potential of the battery and to test the alternator With this device you cannot overcharge the battery e Info Only charge the battery with the specified battery charge This is the only way to ensure that a charging voltage of 14 4 V is not exceeded L02792 10 Switch off the battery charger after charging Disconnect the battery Finishing work Mount the seat
117. rs are in the same position relative to the reference marks The rear wheel is then correctly aligned Tighten nuts sure that chain adjusters o are fitted correctly on adjusting screws Tighten nut Guideline Nut rear wheel spindle M25x1 5 90 Nm 66 4 Ibf ft e Info I The wide adjustment range of the chain adjusters enables different sec ondary ratios with the same chain length Chain adjusters o can be turned by 180 Finishing work Remove the motorcycle from the lift stand p 44 12 32 Checking the chain rear sprocket engine sprocket and chain guide Preparatory work Raise the motorcycle with the lift stand p 44 Main work Shift gear to neutral 6 9 6 9 Check the rear sprocket and engine sprocket for wear gt Ifthe rear sprocket and engine sprocket are worn Change the drivetrain kit e Info The engine sprocket rear sprocket and chain should always be replaced together 400227 01 Pull on the upper part of the chain with the specified weight Guideline Weight chain wear measurement 10 15 kg 22 39 Ib Measure the distance o of 18 chain links in the lower chain section e Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance at the longest 272 mm 10 71 in chain section gt Ifthe distance o Is greater than the
118. rty or wet brake system by riding and braking gently After cleaning ride the vehicle a short distance until the engine warms up e Info The heat produced causes water at inaccessible locations in the engine and on the brake system to evaporate Push back the protection caps of the handlebar controls to allow any water that has penetrated to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 60 reat bare metal except for brake discs and the exhaust system with a corrosion inhibitor Preserving materials for paints metal and rubber p 125 Treat all plastic parts and powder coated parts with a mild cleaning and care prod uct Special cleaner for glossy and matte paint finishes metal and plastic surfaces p 125 Dil the steering lock Universal oil spray p 126 19 CLEANING CARE 97 19 2 Checks and maintenance steps for winter operation e Info If you use the motorcycle in winter you can expect salt on the roads Precautions need be taken against the aggressive road salt If the vehicle was operated in road salt clean it with cold water after riding Warm water would enhance the corrosive effects of salt Clean the motorcycle p 96 Clean the brake system e Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This s
119. s 12 SERVICE WORK ON THE CHASSIS 67 W d b 1L027 64 10 f Nig Unlock quick releases Swing the trim forward and take it off Position the trim on the opposite part of the radiator Swing the trim upward and hook into guides Lock quick releases 12 SERVICE WORK ON THE CHASSIS 68 Connect plug in connectors of the turn signals Remove screws Take off the engine guard the front 12 44 Installing the engine guard 2 Loi NQ gt 4 a INA k 22 l 4 2 4 s e a Position the motor guard Mount and tighten screws Q Guideline Screw motor guard M8 25 Nm 18 4 Ibf ft L02755 10 13 BRAKE SYSTEM 69 13 1 Checking the free travel on the hand brake lever Warning Danger of accidents Brake system failure If there is no free travel on the hand brake lever pressure builds up on the front brake circuit The front brake can fail due to overheating Adjust the free travel on hand brake lever according to specifications Push the hand brake to the handlebar and check free travel Free travel of hand brake lever 23mm 20 12 in If the free travel does not meet specifications Adjust the free travel of the hand brake lever p 69 13 2 Adjusting the free travel of the hand brake lever Check the free travel on the hand brake lever p 69 Adjust the free travel of the hand brake lever
120. shop only and confirmed in the customer s Service amp Warranty Booklet and in the KTM Dealer net otherwise all warranty claims will be void No warranty claims can be consid ered for damage resulting from manipulations and or alterations to the vehicle Additional information on the guarantee or warranty and the procedures involved can be found in the Service amp Warranty Booklet Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Use operating and auxiliary substances such as fuel and lubricants as specified in the Owner s Manual 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 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 Incorrect adjustment and tuning of the engine and chassis can lead to damage and breakage
121. ssion or safety critical fault Turn signal indicator light flashes green Turn signal is switched on High beam indicator lamp lights up blue High beam is switched on The right low fuel warning lamp lights up orange The fuel level of the rear fuel tank has reached the reserve mark 6 CONTROLS 15 6 10 Fuel pump switch The fuel pump switch Is fitted on the left side of the handlebar Possible states FRONT In this position the fuel pump of the two front fuel tanks is active Only the front fuel tanks empty out REAR In this position the fuel pump of the rear fuel tank is active Only the rear tank empties out The fuel pump switch controls the fuel pumps of both front fuel tanks and the rear fuel tank This model has three separate fuel tanks controlled by a fuel pump switch Two fuel tanks are located in front of the seat and one fuel tank is located beneath the seat The right fuel tank is filled via filler cap and the left fuel tank is filled via filler cap The rear fuel tank is filled via filler cap LO2709 10 6 12 Opening the filler caps Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately he fuel in the fuel tank expands when warm and may emerge if overfilled Follow th
122. ssure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swal lowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Condition The engine is cold 16 COOLING SYSTEM 8 co Stand the motorcycle upright on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level above the radiator 10 mm 0 39 in fins gt If the coolant level does not meet specifications Correct the coolant level Coolant p 124 p m ER Ee E I F3 EZ Ewi 400243 10 Mount the radiator 16 4 Draining the coolant A Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In
123. st time you refuel before taking the motorcycle out of service Fuel additive p 125 Fill up with fuel p 34 Clean the motorcycle p 96 Change the engine oil and oil filter and clean the oil screens p 92 Check the antifreeze and coolant level p 88 Check the tire air pressure p 82 Remove the battery p 84 Recharge the battery p 85 Guideline Storage temperature of battery without O 35 C 32 95 F direct sunshine 401058 01 Charging level of the battery for storage 50 75 Place the vehicle on a dry storage place that is not subject to large temperature variations e Info KTM recommends raising the motorcycle Raise the motorcycle with the lift stand p 44 Cover the vehicle with an air permeable cover or blanket e 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 con dense causing engine parts and the exhaust system to rust Preparing for use after storage Remove the motorcycle from the lift stand p 44 Install the battery p 84 N Perform checks and maintenance steps when preparing for use p 31 Take a test ride e n andi 401059 01 21 TROUBLESH
124. t Finishing work Remove the motorcycle from the lift stand p 44 12 SERVICE WORK ON THE CHASSIS 64 1233 Checking the frame Check the frame for cracks and deformation gt Ifthe frame exhibits cracks or deformation due to a mechanical impact Change the frame e Info A frame that has been damaged due to a mechanical impact must always be changed Repair of the frame is not authorized by KTM Check the swingarm for damage cracking and deformation Ifthe swingarm shows signs of damage cracking or deformation Change the swingarm e Info A damaged swingarm must always be changed Repair of the swingarm is not authorized by KTM 601608 01 Preparatory work Remove the seat p 54 Remove the trim p 66 Remove the engine guard p 68 Remove the front right fuel tank p 58 Main work Check the throttle cable routing Both throttle cables must be routed side by side behind the handlebars and between the right fork leg and frame toward the throttle valve body Ifthe throttle cable is not routed as specified Correct the throttle cable routing _102830 10 Finishing work Install the front right fuel tank p 60 Install the engine guard p 68 Mount the trim p 67 Mount the seat p 55 12 SERVICE WORK ON THE CHASSIS 65 12 36 Checking the rubber grip Check the rubber grips on the handleb
125. t and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swal lowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Condition The engine is cold Stand the motorcycle upright on a horizontal surface Remove the radiator cap Check the coolant antifreeze 2054 94b C 9 13 7549 F gt If the coolant antifreeze does not meet specifications Correct the coolant antifreeze Check the coolant level in the radiator Coolant level above the radiator 10 mm 0 39 in fins gt Ifthe coolant level does not meet specifications E a Correct the coolant level Coolant p 124 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 pre
126. the bike again e Info Never leave the key in the steering lock 19 7 SPEEDOMETER 20 7 1 Speedometer overview Press the button to control different functions Press the button to control different functions e Info When the vehicle is delivered only the SPEED H and SPEED ODO display modes are activated 401761 01 1 2 Activation and test Activating the speedometer The speedometer is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor TR M A2 St 52 Display test To enable you to check that the display is functioning properly all display segments DC light up briefly LAP CLK H 400313 01 WS wheel size After the display function check the wheel size WS is displayed briefly e Info The number 2205 equals the circumference of the 21 front wheel with stan dard tires The display then changes to the last selected mode 400314 01 1 3 Kilometers or miles setting 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 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 M A2 St 2 Z Setup menu is displayed and the active functions are shown
127. the button Z symbol disappears in the display and the next function appears 1 5 Setting the clock Condition The motorcycle is stationary display Press the button for 2 3 seconds Z hour display flashes Wait 3 5 seconds 400330 01 the button and the button Info Repeatedly press the button briefly until CLK appears at the bottom right of the Set the hour display with the button and or button Z 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 c The seconds can only be set to zero If no button is actuated for 15 20 seconds or there is no signal from the wheel speed sensor then the settings are automatically stored and the Setup menu is closed 1 6 Viewing the lap time e Info This function can only be opened if lap times have actually been timed Condition The motorcycle is stationary 7 SPEEDOMETER 22 Repeatedly press the button briefly until LAP appears at the bottom right of the display Briefly press the button Z LAP 1 appears on the left side of the display 200 i The laps 1 10 can be viewed with the button LAP Press and hold the button for 3 5 seconds to clear the lap times Briefly press the button Z Next display mode 400321 01 e Info When a signal from the wheel sp
128. the spoke tension is correct Your authorized KTM workshop will be glad to help Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle Briefly strike each spoke with a screwdriver blade Info ll The frequency of the tone is a function of the spoke length and spoke diam eter If you hear different tone frequencies from individual spokes of the same length and thickness this is an indication of different spoke tensions SN You should hear a high note AN 400694 01 If the spoke tensions differ Correct the spoke tension Check the spoke tension Guideline Spoke nipple front wheel M4 5 5 6 Nm 3 7 4 4 Ibf ft Spoke nipple rear wheel M5 5 6 Nm 3 7 4 4 bf ft 14 WHEELS TIRES B 15 15 1 ELECTRICAL SYSTEM 84 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physicia
129. the vehicle while it is still warm from being run Always let the vehicle cool first Note Material damage Damage to or destruction of components due to excessive load The side stand is only designed for the weight of the motorcycle Do no sit on the motorcycle when it is resting on the side stand The side stand or the frame may become damaged and the motorcycle may fall over Brake the motorcycle Shift gear to neutral Park the motorcycle on firm ground 9 7 Transport Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Note Fire hazard Some vehicle components become very hot when the vehicle is operated Do not park the vehicle near flammable or explosive substances Do not place objects on the vehicle while it is still warm from being run Always let the vehicle cool first Switch off the engine Use tension belts or other suitable devices to secure the motorcycle against acci dents or falling over a 401475 01 9 RIDING INSTRUCTIONS 34 9 8 Refueling Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on r
130. toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight Finishing work Check the engine oil level p 92 Install the engine guard p 68 18 3 Adding engine oil e Info Too little engine oil or poor quality engine oil results in premature wear to the engine Main work Remove oil filler plug with the O ring from the clutch cover Fill engine oil to the middle O of the level viewer Add the same engine oil that was used when the motor was changed Engine oil SAE 10W 50 p 124 e Info For optimal performance of the engine oil do not mix different types of engine oil We recommend making an oil change in this case Install and tighten the oil filler plug with O ring Danger A Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight Finishing work Check the engine oil level p 92 19 CLEANING CARE 96 19 1 Cleaning the motorcycle Note
131. tton Press the button No function for 2 3 seconds Briefly press the Activates Mph display button Press the button No function for 2 3 seconds Wait 3 5 seconds Changes to the next display changes from selection to the Setup menu Wait 10 12 sec Saves and closes the Setup menu onds 1 11 Display mode SPEED CLK time Repeatedly press the button briefly until CLK appears at the bottom right of the display 400329 01 The time is shown in display mode CLK Press the button The display changes to the Setup menu of the clock for 2 3 seconds Briefly press the Next display mode button r 01 UI IC E T CLK Press the button No function for 2 3 seconds Briefly press the No function button 400319 01 7 SPEEDOMETER 24 7 12 Setting the clock Condition e he motorcycle is stationary Repeatedly press the button briefly until CLK appears at the bottom right of the display 2 r 0 LI Press the button for 2 3 seconds Press the button Increases the value for 2 3 seconds Briefly press the Increases the value button IL DILI C 1 CLK 400319 01 Press the button Reduces the value for 2 3 seconds Briefly press the Reduces the value button Wait 3 5 seconds Changes to the next value Wait 10 12 sec Closes the SETUP menu onds 1 13 Display mode SPEED LAP lap time Repeate
132. ule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid is corrosive Use only clean brake fluid from a sealed container 13 BRAKE SYSTEM 7 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 124 Position cover with membrane Mount and tighten screws Q e Info Clean up overflowed or spilt brake fluid immediately with water SE ered 10276910 13 6 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help Note Danger of accidents Reduced braking efficiency caused by damaged brake discs Ifthe brake linings are not changed in time the steel brake lining carriers grind on the brake disc The braking effect is greatly reduced and the brake discs are destroyed Check the brake linings
133. ure distance of rear wheel unloaded p 38 With another person holding the motorcycle the rider wearing full protective cloth ing sits on the seat in a normal sitting position feet on footrests and bounces up and down a few times Z rear wheel suspension levels out Another person now measures the distance between the rear axle and a fixed point Note down the value as dimension Q e Info The riding sag is the difference between measurements O and Check the riding sag Riding sag 100 mm 3 94 in gt If the riding sag differs from the specified measurement Adjust the riding sag p 40 11 TUNING THE CHASSIS 40 11 9 Adjusting the spring preload of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury he shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help e Info Before changing the spring preload make a note of the present setting e g by measuring the length of the spring Preparatory work Raise the motorcycle with the lift stand p 44 Remove the seat p 54 Remove the main silencer p 56 Remove the shock absorber p 51 After removing the shock absorber clean it thoroughly Main work Loosen screw Q Turn adjusting ring o until the spring is no longer under tension
134. with adjusting screw e Info 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 pres sure 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 Reduced braking efficiency due to worn brake disc s Change the worn brake disc s without delay Your authorized KTM workshop will be glad to help Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement e Info Wear reduces the thickness of the brake disc around the area used by the brake linings Brake discs wear limit Ifthe brake disc thickness is less than the specified value Change the brake disc Check the front and rear brake discs for damage cracks and deformation f damage cracks or deformation are visible on the brake disc 400257 10 Change brake disc 13 BRAKE SYSTEM 70 13 4 Checking the front brake fluid level Warning Danger of accidents Brake system failure If the brake fluid level drops below the specified marking or the specified value this is an indication that the brake system Is leaking or that the brake linings are completely worn
135. y mode SPEED A2 average speed 2 Repeatedly press the button briefly until A2 appears at the top right of the dis play 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 e Info The displayed value can differ from the actual average speed if 2 was not stopped after the ride Briefly press the Next display mode button Press the button No function for 2 3 seconds Press the button No function for 2 3 seconds 400326 01 Briefly press the No function button 7 SPEEDOMETER 27 7 21 Display mode SPEED S1 stop watch 1 Repeatedly press the button briefly until S1 appears at the top right of the dis play 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 1 r n n The calculation of this value starts with the first impulse from the wheel speed sensor ULP 23 and ends 3 seconds after the last impulse ress the button Displays of TR1 A1 and S1 are reset to 0 0 for 2 3 seconds Briefly press the Next display mode button Press the button No function for 2 3 seconds Briefly press the No function button 1 22 Display mode SPEED S2 stop watch 2 Repeatedly press the button briefly until S2 appears at the top right of the dis play S2 Stop watch 2 is a manual

12 service work on the chassis

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