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KTM KTM 690 Duke ABS 2015 User Manual PDF

1. seeeees 62 10 2 Adjusting the compression damping of the fork DUK GAR saa tete ERAI DM CIN 62 10 3 Adjusting the rebound damping of the fork AI Cua moanne a E REEE 63 11 10 4 Compression damping of the shock absorber DUKE Lm 10 5 Adjusting the high speed compression damping of the shock absorber Duke R zm 10 6 Adjusting the low speed compression damping of the shock absorber Duke R EE 10 7 Adjusting the rebound damping of the shock absorber Duke R ccesseceeeeceeeeeessseeeseseeeseseeess 10 8 Adjusting the spring preload of the shock absorber ee 10 9 Adjusting the TOOtreS S A AEE E 10 10 Adjusting the foot brake lever stub Duke R SERVICE WORK ON THE CHASSIS le 11 1 Raising the motorcycle with the rear wheel SANO mesita QR 11 2 Taking the motorcycle off of the rear wheel Stand A sari kel W 11 3 Raising the motorcycle with the front wheel icm 11 4 Taking the motorcycle off of the front wheel jpg 11 5 Removing the passenger seat 11 6 Mounting the passenger seat 11 7 Removing the passenger seat cover Duke R 11 8 Mounting the passenger seat cover Duke R 11 9 Checking the chain for dirt usesssss 11 10 Cleaning the chal cion E 11 11 Checking the chain tension U UU U E U 11 12 Adjusting the chain ten
2. Universal oil spray p 184 18 2 Checks and maintenance steps for winter operation Info road salt If you use the motorcycle in winter you must expect salt on the roads You should therefore take precautions against aggressive If the vehicle was operated in road salt clean it with cold water after riding Warm water would enhance the corrosive effects of salt do E i gt i N XE A OvO 4 X 401060 01 Clean the motorcycle p 150 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 should be done after the parts are cooled down and while they are installed After use on salted roads clean the motorcycle thoroughly with cold water and dry it properly Treat the engine the swingarm and all other bare or galvanized parts except brake discs with a wax based anti corrosion substance e Info To prevent serious reduction of the braking efficiency make sure no anti corrosion substance gets on to the brake discs Clean the chain p 78 19 19 1 STORAGE Storage 153 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 work
3. 16 2 Checking the basic position of the shift lever 16 3 Adjusting the basic position of the shift lever HH HHHMNE N SERVICE WORK ON THE ENGINE 4k kkee 17 1 Checking the engine oil level 17 2 Changing the engine oil and filter cleaning the oll SCreens A ec tnr Enea ane eh TABLE OF CONTENTS 17 3 Adding engine Oil ke CLEANING CARE 4 tal cee ating Ae ise kek sd vak xe ekey ues 18 1 Cleaning the motorcycle UUU 18 2 Checks and maintenance steps for winter operation ete OE STORAGE desear did el babe e dante Heres ka etes lacreet via I9 l Storage ERI RM 19 2 Preparing for use after storage TROUBLESHOOTING FLASH CODE waists recette tiet ote de e eve eve E e e needed TECHNICAL DATA coito roda iii 225 1 enge e xane oe citer Gees e HUN 22 2 Engine tightening torques ssssse 223 i Capacities x ai en kn e aA sas Teco cias 2233 1 Engine oil 22 3 2 lt GOON thinset notis ble kan x d eile kd ad 22 3 3 22 AY CHASSIS cae daku NE 22 5 Electrical System u e ROI ce aa Zeb r 2216 Ties aee e gad eo itis e LU aos 22 7 EOFK ys Eye e v er da ees 22 71 BURE sete guest nen eU 22 2 D ke Reese erede rra el ee ep a 22 8 Shock absorber nen nik eene tia E oc cape das 22 81 Duke ot cete irse ke an bi 22 8 2 Duke Ridge cerent e l n n k e k cdi 22 9 Chassis tightening torques EU
4. 23 Sil Stand aaa aae RR Re 43 Spare parts ta LEA hat 13 Starting uius Au Ores RS dress dedi E 49 Steering lock 3 j vno n ERR et Eu dg S BRA 29 Stoppliip 52 cose ec etx ssh ee E 56 Storape TIPP ET 153 154 T Technical data CAPACITIES xx ala 2k e cand eect dote ADR RS ARE Iva 169 Chassis escena d ap nee dee eae eke Same 170 chassis tightening torques 20 000e0 eae 176 electrical system 2 ee 172 ENBIMe vc Anthea LM lb hd tN eue eae 165 179 engine tightening torques o oooooooooooo o 166 TORK seat eins se A ae kde Mee Su eher 173 INDEX Shock abSorber avia ieee ote Ken aa ales 174 TOS e dake dh helk d w BO Eh SSS 172 Throttle grip oo vina kulen a kak e WAA 25 Tire air pressure CHECKING aries A Reg a eee 113 Tire condition CHECKING orcas Ta REPE TAS 111 Toolset umi k d dken bose see cab ee wae ab ee pesa 40 Transport corr IE Qe eh AAA AH AC e 57 Troubleshooting o o o ooooooo o 155 157 Turn signal bulb changing da A A hs ee C NOT eda ome 130 Turn signal switch o o o o o KIRR KK ee eee 27 Type label lt acy bees he ee wae RR PASS 20 Use definition 4 4 2 lc ala wale td awa fed tea de a 8 View of vehicle lefETrONt a BA orien halen alata ee Slats Soho du sus 16 right teal du isch e A Dk bie SEES 18 Warranty gt 5 x K na va Ak a hd ERE Ede LER D 13 Winter operation checks and maintenance steps
5. Super unleaded ROZ 95 RON 95 PON 91 p 182 22 4 Chassis Frame Lattice frame made of chrome molybdenum steel tubing powder coated Fork Duke WP Suspension Up Side Down 4357 Fork Duke R WP Suspension 4357 ROTA SPLIT Shock absorber Duke WP Suspension emulsion with Pro Lever linkage Shock absorber Duke R WP Suspension 4618 with Pro Lever deflector Suspension travel Duke Front 135 mm 5 31 in Rear 135 mm 5 31 in Suspension travel Duke R Front 150 mm 5 91 in Rear 150 mm 5 91 in Brake system Front Disc brake with radially screwed four piston brake caliper floating brake disc Rear Disc brake with single piston brake caliper floating Brake discs diameter 22 TECHNICAL DATA 171 Front 320 mm 12 6 in Rear 240 mm 9 45 in Brake discs wear limit Front 4 2 mm 0 165 in Rear 4 5 mm 0 177 in Tire air pressure solo Front 2 0 bar 29 psi Rear 2 0 bar 29 psi Tire air pressure with passenger fully loaded Front 2 0 bar 29 psi Rear 2 2 bar 32 psi Secondary drive ratio 16 40 Chain 5 8 x 1 4 520 X ring Steering head angle 63 5 Wheelbase 1 466 15 mm 57 72 0 59 in Seat height unloaded Duke 835 mm 32 87 in Seat height unloaded Duke R 865 mm 34 06 in Ground clearance unloaded 1
6. Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Fix the hand brake lever in the acti Screw front brake caliper M10x1 25 45 Nm 33 2 Ibf ft Loctite 243 Remove the fixation of the hand brake lever Take the motorcycle off of the front wheel stand p 75 Take the motorcycle off of the rear wheel stand p 73 13 WHEELS TIRES 106 Pull the front brake and compress the fork forcefully a few times Y The fork legs straighten Tighten screws Guideline Screw fork stub M8 15 Nm 11 1 Ibf ft 13 3 Removing the rear wheel A Preparatory work Raise the motorcycle with the rear wheel stand p 73 Main work Remove screw and pull wheel speed sensor out of the hole Remove nut Remove chain adjuster L T O le gt J b 12 2 J 2 Z M00665 10 13 WHEELS TIRES A M00666 10 107 Withdraw wheel spindle 5 only enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket e Info Cover the components to protect them against damage Hold the rear wheel and remove the wheel spindle Pull the rear wheel back until the brake caliper support is suspended freely between the brake disc and rim Warning Danger of accidents Reduced br
7. Lock the steering by turning the handlebar fully to the left pressing down the ignition key to the position amp and turning it to the posi tion A To make the steering lock engage more easily move the handlebar a little to the left and right Remove the ignition key 8 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 8 RIDING INSTRUCTIONS 58 Switch off the engine Use tension belts or other suitable devices to secure the motorcycle against accidents or falling over mem 8 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 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
8. Map Select switch Light switch p 26 Headlight flasher switch p 27 Turn signal switch p 27 Horn button p 26 Filler cap Ignition steering lock p 29 Emergency OFF switch p 28 Electric starter button p 28 Hand brake lever p 24 Chassis number p 20 Fuse box O 0 N OS O OI Bl WI PM PM MM 9 a Type label p 20 Passenger footrests p 41 mjm O Foot brake lever p 43 rA N Level viewer engine oil 5 SERIAL NUMBERS 20 A o AS Re The type label is located on the right side of the frame 402294 10 The chassis number O is stamped on the right side of the steering head 5 SERIAL NUMBERS 21 690 Duke R AU Additional type label is located on the left side of the frame 402381 11 The key number can be found on the KEYCODECARD e Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place KEYCODECARD 1234 O Kin 402241 10 5 SERIAL NUMBERS 22 54 Engine number 000 The engine number is located on the left side of the engine under the engine sprocket 401949 10 The fork part number is stamped on the inner side of the fork stub 9 402295 10 5 SERIAL NUMBERS AA 402382 10
9. Piston rings 1 L ring 1 tapered compression piston ring 1 oil scraper ring Engine lubrication Semi dry sump lubrication system with two rotor pumps Primary transmission 36 79 Clutch APTC antihopping clutch in oil bath hydraulically operated Transmission 6 gear claw shifted Transmission ratio lst gear 14 35 2nd gear 16 28 3rd gear 21 28 Ath gear 21 23 22 TECHNICAL DATA 166 5th gear 23 22 6th gear 23 20 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V 224 W Spark plug Inside spark plug NGK LKAR8BI 9 Outside spark plug NGK LMAR7A 9 Spark plug electrode gap 0 9 mm 0 035 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 550 1 650 rpm Starting aid Electric starter automatic decompressor 22 2 Engine tightening torques Screw membrane fixation M3 2 Nm 1 5 Ibf ft Loctite 243 Hose clamp intake flange M4 2 5 Nm 1 84 Ibf ft Oil nozzle for conrod bearing lubrication M4 2 Nm 1 5 Ibf ft Loctite 2437 Locking screw for bearing M5 6 Nm 4 4 Ibf ft Loctite 2437 Remaining screws engine M5 6 Nm 4 4 Ibf ft Screw breather cover on valve cover M5 6 Nm 4 4 Ibf ft Loctite 243 Screw clutch spring
10. Fuel Stabilizer Recommended supplier Motorex Bike Grease 2000 Recommended supplier Motorex Moto Clean 24 AUXILIARY SUBSTANCES 184 Recommended supplier Motorex Moto Polish amp Shine Recommended supplier Motorex Moto Protect Recommended supplier Motorex Quick Cleaner Recommended supplier Motorex Joker 440 Synthetic 25 STANDARDS 185 JASO T903 MA 00000000 Different technical development directions required a new specification for 4 stroke motorcycles the JASO T903 MA Standard Ear lier engine oils from the automobile industry were used for 4 stroke motorcycles because there was no separate motorcycle specification Whereas long service intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Stan dard 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 viscos ity The viscosity describes only one property of oil and says nothing about quality A ABS os east eret at a had ek ta tia Ct Beta Sa eG 87 ACCESSOMCS 3 55 rea Se Hee pa ae Ree AG 13 Antifreeze CHECKING A e daka Waleed hae 133 Antilock brake system LL AV A VI KK KII KI eee ee 87 Auxiliary substances LL LL AV VV KIRI
11. 11 3 Raising the motorcycle with the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Preparatory work Raise the motorcycle with the rear wheel stand p 73 Main work Move the handlebar to the straight ahead position Attach the lifting gear to the steering stem Adapter 61029955620 Front wheel stand 61029055500 e Info Always raise the rear of the motorcycle first 602543 01 11 SERVICE WORK ON THE CHASSIS 75 Raise the front of the motorcycle Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Secure the motorcycle against falling over Remove the front wheel stand 4 Insert the ignition key in seat lock o and turn it clockwise Raise the rear of the passenger seat push it towards the rear and remove it upward Remove the ignition key from the seat lock 11 SERVICE WORK ON THE CHASSIS 76 11 6 Mounting the passenger seat Hook catches of the passenger seat onto the storage compartment lower the rear and simultaneously push forward Press down the passenger seat until it clicks into place Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly After mounting the passenger seat check
12. 13 WHEELS TIRES Clean screw 1 and wheel spindle e Lift the front wheel into the fork position it and insert the wheel spindle Y The arrow on the spoke points in the direction of motion Mount and tighten screw O Guideline 104 Screw front wheel spindle M24x1 5 45 Nm 33 2 Ibf ft Position wheel speed sensor e in the drill hole Mount and tighten screw O Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft Position the brake caliper Y The brake linings are correctly positioned Position spacers Mount screws but do not tighten yet Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Fix the hand brake lever in the acti vated position Y The brake calipers straighten Tighten screws Guideline Screw front brake caliper M10x1 25 45 Nm 33 2 Ibf ft Loctite 243 13 WHEELS TIRES Duke R Guideline 105 Position wheel speed sensor e in the drill hole Mount and tighten screw O Remaining screws chassis M6 10 Nm 7 4 Ibf ft Position the brake caliper vated position Y The brake calipers straighten Tighten screws O Guideline Y The brake linings are correctly positioned Position spacers Mount screws but do not tighten yet
13. 402298 10 Duke Shock absorber article number 1 is located on the left side of the shock absorber Duke R Shock absorber article number o is located on the back of the shock absorber 23 6 CONTROLS 24 61 Chthlever 00 The clutch lever 1 is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting Duke The hand brake lever 1 is fitted on the right side of the handlebar i 602570 10 6 CONTROLS 25 Duke R The hand brake lever is fitted on the right side of the handlebar The front brake is engaged using the hand brake lever 602552 10 The throttle grip is fitted on the right side of the handlebar B00922 10 6 CONTROLS 26 The horn button is fitted on the left side of the handlebar M00655 10 Possible states e Horn button in neutral position e Horn button pressed The horn is operated in this position The light switch is fitted on the left side of the handlebar M00656 11 Possible states z gt Low beam on Light switch is turned downwards In this position the low beam and tail light are switched on D High beam on Light switch is turned upwards In this position the high beam and the tail light are switched on 6 CONTROLS 27 6 6 Headlight flasher switch The headlight flasher switch 1 is fitted on the left
14. Screw main silencer fixation M8 25 Nm 18 4 Ibf ft Screw rear brake disc M8 30 Nm 22 1 Ibf ft Loctite 27017 Screw side stand bracket M8 25 Nm 18 4 Ibf ft Loctite 243 Screw spring holder on side stand M8 25 Nm 18 4 Ibf ft Loctite 243 bracket Screw top triple clamp M8 17 Nm 12 5 Ibf ft Engine carrying screw M10 45 Nm 33 2 Ibf ft Loctite 2437 22 TECHNICAL DATA 179 Remaining nuts chassis M10 45 Nm 33 2 Ibf ft Remaining screws chassis M10 45 Nm 33 2 Ibf ft Screw foot brake lever Duke M10 25 Nm 18 4 Ibf ft Screw handlebar support M10 20 Nm 14 8 Ibf ft Screw side stand M10 35 Nm 25 8 Ibf ft Loctite 243 Screw subframe M10 45 Nm 33 2 Ibf ft Loctite 243 Banjo bolt brake line M10x1 25 Nm 18 4 Ibf ft Banjo bolt pressure modulator M10x1 25 Nm 18 4 Ibf ft Screw bottom shock absorber M10x1 25 50 Nm 36 9 Ibf ft Loctite 243 Screw front brake caliper M10x1 25 45 Nm 33 2 Ibf ft Loctite 243 Screw top shock absorber M10x1 25 50 Nm 36 9 Ibf ft Loctite 243 Lambda sensor M12x1 25 25 Nm 18 4 Ibf ft Nut frame to linkage lever M14x1 5 100 Nm 73 8 Ibf ft Nut linkage lever on swingarm M14x1 5 100 Nm 73 8 Ibf ft Nut linkage lever to rocker arm M14x1 5 100 Nm 73 8 Ibf ft Nut swingarm pivot M16x1 5 100 Nm 73 8 Ibf ft Screw steering head M20x1 5 40 Nm 29 5
15. 000 152 MorKTUles zara O wena sae 11 190 WWW KTM COM 3213272en 10 2014 KTM Motorrad AG 5230 Mattighofen Austria http www ktm com mo Ey REGNO 13 1006061 Photo Mitterbauer KTM
16. 18 4 Ibf ft Nut manifold on cylinder head M8 20 Nm 14 8 Ibf ft Copper paste Nut rear sprocket screw M8 35 Nm 25 8 Ibf ft Loctite 27017 Remaining nuts chassis M8 25 Nm 18 4 Ibf ft Remaining screws chassis M8 25 Nm 18 4 Ibf ft Screw bottom triple clamp M8 12 Nm 8 9 Ibf ft Screw exhaust system M8 25 Nm 18 4 Ibf ft 22 TECHNICAL DATA 178 Screw footrest bracket rear M8x30 25 Nm 18 4 Ibf ft Loctite 243 Screw footrest bracket rear M8x50 25 Nm 18 4 Ibf ft Loctite 243 Screw footrest bracket rear Duke R M8x20 Countersunk screw Loctite 243 25 Nm 18 4 Ibf ft Screw footrest bracket rear Duke R M8x45 Countersunk screw Loctite 243 25 Nm 18 4 Ibf ft Screw fork stub M8 15 Nm 11 1 Ibf ft Screw front brake disc M8 30 Nm 22 1 Ibf ft Loctite 2701 Screw front footrest bracket M8 25 Nm 18 4 Ibf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 Ibf ft Screw handrail M8x30 Countersunk screw Loctite 243 18 Nm 13 3 Ibf ft Screw handrail cover M8x20 18 Nm 13 3 Ibf ft Loctite 243 Screw ignition lock tamper proof M8 Loctite 243 screw Screw license plate holder M8 18 Nm 13 3 Ibf ft Loctite 243 Screw linkage bracket front engine fix M8 25 Nm 18 4 Ibf ft Loctite 243 ing arm Screw main silencer clamp Duke R M8 15 Nm 11 1 Ibf ft
17. Change the spark plugs o Check the valve clearance 4 e e Check all hoses e g fuel cooling bleeder drainage etc and sleeves for cracking leaks and incorrect routing 4 e Check the antifreeze and coolant level p 133 o Check the cables for damage and routing without sharp bends e e Change the air filter Clean the air filter box 4 e o Check the fuel pressure 4 e o Check the CO adjustment with the KTM diagnostics tool 4 e o Check rectify the fluid level of the hydraulic clutch p 86 Check the screws and nuts for tightness o o e Change the front brake fluid amp e Change the rear brake fluid e Check the headlight setting p 131 o oe e Check that the radiator fan is functioning properly A o e Final check Check the vehicle for roadworthiness and take a test ride o e e Read out the fault memory using the KTM diagnostics tool after a test ride o e e Make the service entry in the KTM Dealer net and in the Service and Warranty Booklet o e o One time interval e Periodic interval 10 TUNING THE CHASSIS 62 10 1 Fork shock absorber Duke R The fork and the shock absorber offer many options of adapting the chassis to your riding style and the payload e Info To help you adapt the vehicle we have summarized our findings in Table You can find the table on the subframe under the passenger seat These adjustments should be understood as a guideline and should alway
18. Fork WP Suspension 4357 ROTA SPLIT Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks Spring length with preload spacer s 303 mm 11 93 in 22 TECHNICAL DATA 174 Spring rate Medium standard 6 5 N mm 37 1 Ib in Air chamber length 80x20 mm 3 15 0 79 in Fork length 831 mm 32 72 in Fork oil per fork leg 534 ml 18 05 fl oz Fork oil SAE 4 4860116651 p 181 22 8 Shock absorber 22 8 1 Duke Shock absorber part number 01 18 7N 19 Shock absorber WP Suspension emulsion with Pro Lever linkage Spring preload Standard 4 clicks Static sag 20 mm 0 79 in Riding sag 45 mm 1 77 in Fitted length 364 mm 14 33 in 22 8 2 Duke R Shock absorber part number 15 18 7M 11 Shock absorber WP Suspension 4618 with Pro Lever deflector Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn 22 TECHNICAL DATA 175 Full payload 1 turn Compression damping low speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full pay
19. Minimum thickness gt 1 mm gt 0 04 in Ifthe minimum thickness is less than specified Change the front brake linings 4 Check the brake linings for damage and cracking If there is damage or cracking Change the front brake linings 4 12 7 Checking the free travel of 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 over heating Adjust the free travel on foot brake lever according to specifications Disconnect spring O 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 O Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Ifthe free travel does not equal the specification Adjust the basic position of the foot brake lever 4 p 95 Attach spring O 12 BRAKE SYSTEM 95 Duke R Disconnect spring 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 O Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Ifthe free travel does not equal the specification Adjust the basic position of the foot brake lever 4 p 95 Attach spring Q 12 8 Adjusting the basic pos
20. tension O e Info I The upper chain section o must be taut Chain wear is not always even Repeat this measurement at different chain posi tions Chain tension 5 mm 0 2 in Ifthe chain tension does not meet specifications Adjust the chain tension p 81 f 801000 10 11 SERVICE WORK ON THE CHASSIS 81 11 12 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 bearings 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 Check the chain tension p 79 11 SERVICE WORK ON THE CHASSIS Main work Loosen nut Loosen nuts e Guideline 82 Adjust the chain tension by turning adjusting screws e left and right Chain tension 5 mm 0 2 in rear wheel is then correctly aligned Turn adjusting screws e on the left and right so that the markings on the left and right chain adjusters o are in the same position relat
21. A Warning Danger of accidents Unstable handling characteristics Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational and with a full tank driver and passenger with protective clothing and helmet baggage Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and or tank rucksack Mount and secure suitcase and tank rucksack according to the manufacturer s instructions Warning Danger of accidents Unstable handling characteristics at high speed Adapt your speed according to your payload Ride more slowly if your motorcycle is loaded with cases or other baggage Maximum speed with baggage 130 km h 80 8 mph Warning Danger of accidents Risk of breakage of suitcase system f you have fitted suitcases on your motorcycle read the manufacturer s specifications concerning the maximum payload Warning Danger of accidents Poor visibility for other road users due to slipped baggage If the tail light is covered you are less visible to traffic behind you especially in the dark Check that your baggage is fixed properly at regular intervals Warning Danger of accidents Changed handling characteristics and longer stopping distance with excessive payload Adapt your speed according to your payload 7 PREPARING FOR USE 41 Warning Danger of accidents Unstable handling characteristics due to slipped baggag
22. CONTROLS 29 The ignition steering lock is located in front of the upper triple clamp Possible states be removed Ignition on In this position the ignition circuit is closed and the engine Ignition off In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start The ignition key can C can be started Steering locked In this position the ignition circuit is interrupted and the steering locked The ignition key can be removed 6 11 1 Overview The combination instrument is installed in front of the handlebar The combination instrument is divided into 4 function areas O Function buttons p 30 Tachometer p 30 Indicator lights p 31 O Display p 32 t 401420 10 6 CONTROLS 30 6 11 2 Function buttons You can change the display mode with the MODE button Possible display modes are the odometer ODO trip master 1 TRIP 1 trip master 2 TRIP 2 and gear display GEAr Press the SET button to reset the trip master 1 function TRIP 1 and trip master 2 func tion TRIP 2 to 0 0 The ABS can be switched off using button O 6 11 3 Tachometer The tachometer 1 shows the engine speed in revolutions per minute The orange marking 2 marks the over rev excessive speed range of the engine 401427 10 6 CONTROLS 31 6 11 4 Combination instrument i
23. Engine dies during the trip Lack of fuel Refuel p 58 Fuse 1 2 or 3 blown Change the fuses of individual power consumers p 122 The ABS warning lamp lights up ABS fuse is blown Change the ABS fuses p 121 Large difference in wheel speeds of the front and rear wheels Stop the vehicle switch off the ignition and start it again Malfunction in ABS Read out the ABS fault memory using the KTM diagnostics tool High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary 20 TROUBLESHOOTING 157 Faults Possible cause Action High oil consumption Engine oil level too high Check the engine oil level p 144 Engine oil too thin low viscosity Change the engine oil and filter clean the oil screens amp p 144 Headlight and parking light are not Fuse 6 blown Change the fuses of individual power consumers functioning p 122 Turn signal brake light and horn are Fuse 5 blown Change the fuses of individual power consumers not functional p 122 Time is not correctly displayed Fuse 1 blown Change the fuses of individual power consumers 7 p 122 Set the clock p 34 Battery discharged Ignition not switched off when vehicle was park ed Recharge the battery 4 p 116 Battery is not charged by alternator Check the charging vo
24. Ibf ft Loctite 243 C00330 10 10 TUNING THE CHASSIS JD Mount the rider footrest with the spring and pin Mount lock ring C00329 10 10 TUNING THE CHASSIS Remove screw along with the foot brake lever stub Position foot brake lever stub along with screw in the desired drilled hole Guideline Standard Front drilled hole Tighten the screw Guideline Screw foot brake lever stub M6 10 Nm Loctite 243 7 4 Ibf ft lt ae 101968 10 73 11 SERVICE WORK ON THE CHASSIS 11 1 Raising the motorcycle with the rear wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Mount the support of the wheel stand Insert the adapter in the rear wheel stand Adapter 61029055120 Rear wheel stand 61029055400 Stand the motorcycle upright align the lifting gear with the swingarm and the adapters and lift the motorcycle 602544 01 11 2 Taking the motorcycle off of the rear wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 11 SERVICE WORK ON THE CHASSIS 74 Secure the motorcycle against falling over Remove the rear wheel stand and lean the vehicle on the side stand C00312 11
25. Ibf ft Adjusting ring of swingarm bearing M24x1 5 25 Nm 18 4 Ibf ft Screw front wheel spindle M24x1 5 45 Nm 33 2 Ibf ft Nut rear wheel spindle M25x1 5 90 Nm 66 4 Ibf ft Nut steering head M28x1 12 Nm 8 9 Ibf ft 23 SUBSTANCES 180 Standard classification DOT Guideline Use only brake fluid that complies with the specified standard see specifications on the container and that exhibits the corresponding properties Recommended supplier Castrol 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 inferior antifreeze can result in corrosion and foaming Mixture ratio Antifreeze protection 725 45 C 13 anti corrosion antifreeze 49 F distilled water Recommended supplier Motorex COOLANT M3 0 Standard classification JASO T903 MA p 185 SAE p 185 SAE 10W 60 23 SUBSTANCES 181 KTM LC4 2007 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Synthetic engine oil Recommended supplier Motorex Cross Power 4T Standard classification JASO T903 MA p 185 SAE p 185 SAE 10W 50 Guideline Use only engine oils that comply with t
26. KK KII KI KII KIR 13 B Baosage ios ai b al nan salla sdb a 46 Battery TIS i N sos um ade ne mtm m oad eden De 115 recharging Ass d ku ed d a a 116 FEMOVING o sets Siren ota AN E ENTE oe B Den ERK 114 Brake discs CHECKING 2 b bo d n a A ds K al dd es b d n aa es dike 89 Brake fluid front brake adding kk KK KI KI KIRI K K eee 91 rear brake adding kk kk kk kk kK KI KI KI KIRI KI KIRI KIRI KI KI KI KK 98 Brake fluid level front brake checking kk KK KRI RI KI KI KK KI K K eee 90 rear brake checking kk KK llle 98 Brake linings front brake checking Sk kK KE KRI KI KIR KI K K KI KI 93 rear brake checking kk kK K R RIK KI KIRI III 100 Brake system 0 0 cee ee es 87 101 186 Brakes ma t sce xen eur sues It aod pete tos SE oed 54 Brakes applying KRI KIR KIRI RIK KI eee 54 C Capacity Coolant x i ae o p a T ED aa a a a E A a aa 170 engltg OM Sara ae ca aa ra c k is Re 148 169 A i artan E E heehee 59 170 Chain Checkin sarriena ya wena eee ee WI be Se 83 CLEANING a za yA aa tants Qala dr wedge ae diosa 78 dirt checking for rx bu x al eet 77 Chain tension adjusting acest A ARUM eam REA 81 CHECKING ue beca eus ee 79 Chassis number 0000 k eee eee 20 Clutch fluid level checking correcting o o o o oooo o 86 Clutch levet a 2i SAL ala ava la eee a xs 24 basic position adjusting o oooooo
27. M5 4 Nm 3 Ibf ft Chain guard M6 4 Nm 3 Ibf ft Loctite 243 Double sided grub screw M6 6 Nm 4 4 Ibf ft Loctite 243 Nut push rod foot brake lever Duke R M6 6 Nm 4 4 Ibf ft Remaining nuts chassis M6 10 Nm 7 4 Ibf ft Remaining screws chassis M6 10 Nm 7 4 Ibf ft 22 TECHNICAL DATA 177 Screw ball joint of push rod on foot M6 10 Nm 7 4 Ibf ft Loctite 2437 brake cylinder Screw battery terminal M6 2 Nm 1 5 Ibf ft Screw brake fluid reservoir of rear brake M6 5 Nm 3 7 Ibf ft Screw chain sliding guard M6 10 Nm 7 4 Ibf ft Loctite 2437 Screw control unit holder M6 3 Nm 2 2 Ibf ft Screw exhaust pipe clamp M6 8 Nm 5 9 Ibf ft Copper paste Screw foot brake cylinder M6 10 Nm 7 4 Ibf ft Loctite 2437 Screw foot brake lever stub Duke R M6 10 Nm 7 4 Ibf ft Loctite 243 Screw fuel spoiler M6 3 Nm 2 2 Ibf ft Screw lower radiator bracket M6 5 Nm 3 7 Ibf ft Screw magnetic holder on side stand M6 5 Nm 3 7 Ibf ft Loctite 2437 Screw seat lock M6 10 Nm 7 4 Ibf ft Loctite 222 Screw tail light cover M6 8 Nm 5 9 Ibf ft Screw voltage regulator M6 8 Nm 5 9 Ibf ft Shift rods nut Duke R M6 6 Nm 4 4 Ibf ft Shift rods nut Duke R M6LH 6 Nm 4 4 Ibf ft Main silencer holder Duke R M8x40 25 Nm 18 4 Ibf ft Main silencer holder Duke R M8x60 25 Nm
28. Warning Danger of accidents Failure of brake system 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 e Info When using your vehicle remember that others may feel disturbed by excessive noise Make sure that the pre delivery inspection work has been carried out by an authorized KTM workshop Y You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover Before your first trip read the entire operating instructions carefully Get to know the controls Adjust the basic position of the clutch lever p 85 Adjust the basic position of the hand brake lever p 88 Adjust the basic position of the foot brake lever amp p 95 Get used to handling the motorcycle on a suitable piece of land before making a longer trip Try also to ride as slowly as possible to get a better feel for the vehicle Hold the handlebar firmly with both hands and keep your feet on the footrests when riding Run the engine in p 45 7 2 Running in the engine During the running in phase do not exceed the specified engine speed Guideline Maximum engine speed During the first 1 000 km 620 mi 6 000 rpm After the first 1 000 km 620 mi 7 800 rpm 7 PREPARING FOR USE 46 Avoid fully opening the throttle 7 3 Loading the vehicle
29. and ensure that they can be operated smoothly Check that the electrical equipment is functioning correctly Check that baggage is correctly secured Siton the motorcycle and check the rear mirror setting Check the fuel level 8 RIDING INSTRUCTIONS 49 8 2 Starting Danger Al 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 Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always warm up the engine at low engine speeds Turn the emergency OFF switch to the position Switch on the ignition by turning the ignition key to the position O Y After you switch on the ignition you can hear the fuel pump working for about two seconds The function check of the combination instrument is run at the same time Y The ABS warning lamp lights up and goes back out after starting off Shift gear to neutral Y The green idling speed indicator lamp N lights up B00782 10 Press the electric starter button 8 RIDING INSTRUCTIONS 50 Info Do not press the electric starter button until the combination instrument func tion check is finished When starting DO NOT open the
30. ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swallowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Remove radiator cap M00682 10 Remove bleeder screw O Tilt the vehicle slightly to the right Pour in coolant until it emerges without bubbles at the vent hole and then mount and tighten bleeder screw 2 immediately Coolant p 180 Fill the radiator completely with coolant Mount radiator cap O Lean the vehicle on the side stand a BO0985 10 Check the coolant level in the compensating tank p 135 15 COOLING SYSTEM 139 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 Start the engine and run it until the 5th bar of the temperature indicator lights up Stop the engine and allow it to cool down When the engine is cool check the coolant level in the radiator and if necessary add coolant Check the coolant level in the compensating tank p 135 16 TUNING THE ENGINE 140 16 1 Setting the engine characteristics See mm M00683 10 Prepa
31. brake discs for damage cracks and deformation If damage cracks or deformation are visible on the brake disc Replace the brake disc 12 4 Checking the brake fluid level of the front brake Warning Danger of accidents Brake system failure Ifthe 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 autho rized 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 Duke Move the brake fluid reservoir mounted on the handlebar to a horizontal position Check the brake fluid level in the viewer Ifthe brake fluid has dropped below marking O Add front brake fluid 4 p 91 MO0661 10 12 BRAKE SYSTEM 91 Duke R Move the brake fluid reservoir mounted on the handlebar to a horizontal position Check the brake fluid level in the viewer Ifthe brake fluid has dropped below marking Q Add front brake fluid amp p 91 BS EXEESU 12 5 Adding front brake fluid 0 Warning Danger of accidents Brake system failure Ifthe brake fluid level drops below the specified m
32. cap with the washer and membrane e Info Clean up overflowed or spilt brake fluid immediately with water Warning Danger of accidents Reduced braking efficiency caused by worn brake linings M00664 10 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 12 BRAKE SYSTEM 101 Check the brake linings for minimum thickness O Minimum thickness gt 1 mm gt 0 04 in Ifthe minimum thickness is less than specified Change the rear brake linings 4 Check the brake linings for damage and cracking If there is wear or tearing Change the rear brake linings 4 13 WHEELS TIRES 102 602562 10 Preparatory work Raise the motorcycle with the rear wheel stand p 73 Raise the motorcycle with the front wheel stand p 74 Main work Duke Remove screw 1 and pull wheel speed sensor 2 out of the hole Remove screws e and spacers Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc Pull the brake caliper carefully back from the brake disc and hang i
33. 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 6 CONTROLS 39 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 Lift cover of the filler cap and insert the ignition key in the lock Note Danger of damage Ignition key breakage To take pressure off of the ignition key push down on the filler cap Damaged igni tion keys must be replaced Turn the ignition key 90 clockwise Qa Open the filler cap Fold down the filler cap Turn the ignition key 90 clockwise Push down the filler cap and turn the ignition key counterclockwise until the lock closes Warning Fire hazard Fuel is highly flammable poisonous and harmful to your health After closing the filler cap ensure that it is locked properly Change cloth ing that has been contaminated with fuel Immediately clean contaminated areas on the skin with soap and water M00658 01 Remove the ignition key and close the cover 6 CONTROLS 40 6 14 Seatl ek 00 The seat lock is located on the left side of the vehicle It can be
34. glad to help 10 TUNING THE CHASSIS 65 e Info The high speed setting takes effect during the fast compression of the shock absorber Turn adjusting screw all the way clockwise with a socket wrench e Info Do not loosen fitting e 9 Turn counterclockwise by the number of turns corresponding to the shock absorber j type Guideline Compression damping high speed b Atl Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn e Info Turn clockwise to increase damping turn counterclockwise to reduce damping during fast compression 10 6 Adjusting the low speed compression damping of the shock absorber Duke R Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help 10 TUNING THE CHASSIS 66 e Info The low speed setting takes effect during the slow to normal compression of the shock absorber Turn adjusting screw clockwise with a screwdriver up to the last perceptible click e Info Do not loosen fitting e Turn counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Compression damping low speed b basilar Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payl
35. is permitted only with the express written permission of the copyright owner DEAR KTM CUSTOMER ISO 9001 12 100 6061 FEN 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 1S0 9001 REG NO 12 100 6061 KTM Motorrad AG 5230 Mattighofen Austria TABLE OF CONTENTS 3 1 MEANS OF REPRESENTATION ee 7 5 6 Shock absorber part number 23 1 1 Symbol UsBd tete ai cies 7 6 gt CONTROLS xila syn lA y k a ore eua de il dida lh 24 1 2 Formats Usd N DD DB ll abinde 7 6 1 ClUtch leve aa nettes eue Aw teens 24 2 SAFETY ADV CE sik Kun item a ered b ka neka 8 6 2 Hand brake lever E kek 24 2 1 Use definition intended use kh 8 6 3 Throttle amp rlp i ciii kal ede ec xak abies hebane tos tea 25 2 2 Safety advice sika sona cer DEus 8 6 4 HOM DUTON gees eR da 26 2 3 Degrees of risk and symbols eene 9 6 5 Light SWITCH uie e tenere ent t ntn 26 2 4 Tampering warning eee 9 6 6 Headlight flasher switch ccececeeeeeeeeeeeeeeeees 27 2 5 Safe operation tei tc e t eet 10 6 7 Turn signal Swit Hiss iet de ER d 27 2 6 Protective clothing LE EE 11 6 8 Emergency OFF switch WL Ci E 28 2 43 WORK NUNES iii in et een 11 6 9 Electric Starter Dutton ise iiir ttes 28 2 8 Environ Mts
36. 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 SAFETY ADVICE 11 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 Special tools are necessary for certain tasks The tools are not contained in the vehicle but can be ordered under the number in parenthe ses 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 Loctite 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 If you use your motorcycle responsibly you can ensure that problems and conflicts do not occur To protect the future of the motorcycle sport mak
37. or every 2 years Every 10 000 km 6 214 mi or annually Once after 1 000 km 621 4 mi Check the functioning of the electrical equipment o e Read out the fault memory using the KTM diagnostics tool A o e Check the measured service values with the KTM diagnostics tool e Change the engine oil and filter clean the oil screens 4 p 144 o Check the front brake linings p 93 o Check the rear brake linings p 100 o Check the brake discs p 89 o e Check the brake lines for damage and leakage o e Check the rear brake fluid level 7 p 98 o Check the free travel of the foot brake lever p 94 o Check the shock absorber and fork for leaks O Check the swingarm bearing X o Check the wheel bearing for play 4 e Check the tire condition p 111 o Check the tire pressure p 113 o Check the chain rear sprocket and engine sprocket p 83 Check the chain tension p 79 o e Grease all moving parts e g side stand hand lever chain and check for smooth operation o e Clean the dust boots of the fork legs Check the brake fluid level of the front brake p 90 o 9 SERVICE SCHEDULE 61 Every 20 000 km 12 428 mi or every 2 years Every 10 000 km 6 214 mi or annually Once after 1 000 km 621 4 mi Check the steering head bearing play o o
38. refer to the year of manufacture KTM recommends that the tires are changed regardless of the actual wear at the latest after 5 years Ifa tire is more than 5 years old Change the tires 13 WHEELS TIRES 113 13 7 Checking the tire pressure e Info Low tire pressure leads to abnormal wear and overheating of the tire Correct tire pressure ensures optimal riding comfort and maximum tire service life Remove the protection cap Check the tire pressure when the tires are cold Tire air pressure solo Front 2 0 bar 29 psi Rear 2 0 bar 29 psi Tire air pressure with passenger fully loaded Front 2 0 bar 29 psi Rear 2 2 bar 32 psi 400695 01 Ifthe tire pressure does not meet specifications Correct the tire pressure Mount the protection cap 14 ELECTRICAL SYSTEM 114 SS 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 physician Preparatory work Switch off all power consumers and switch off the en
39. relevant passages e 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 SAFETY ADVICE 2 3 Degrees of risk and symbols 000 Danger Al Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken 1 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 xt Indicates a danger that will lead to environmental damage if the appropriate measures are not taken 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 pur chaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any pe
40. side of the handlebar Possible states e Headlight flasher switch in neutral position e Headlight flasher switch pressed In this position the headlight flasher high beam is actuated k M00656 12 6 7 Turn signal switch The turn signal switch o is fitted on the left side of the handlebar Possible states Turn signal off Left turn signal on Turn signal switch pressed to the left The turn signal switch returns to the center position after activation Right turn signal on Turn signal switch pressed to the right The turn sig nal switch returns to the center position after activation moo655 11 To switch off the turn signal press the turn signal switch towards the switch housing 6 CONTROLS 28 6 8 Emergeney OFF switeh 5595959550 The emergency OFF switch is fitted on the right side of the handlebar Possible states x Emergency OFF switch off In this position the ignition circuit is inter rupted a running engine stops and the engine cannot be started Emergency OFF switch on This position is necessary for operation as the ignition circuit is closed 602553 10 The electric starter button 1 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 602553 11 6
41. starting system is inactive 7 7 1 PREPARING FOR USE 44 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 vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Warning Danger of accidents Reduced road grip with new tires New tires have a smooth rolling surface and therefore cannot provide full road grip The entire rolling surface must be rough ened in the first 200 kilometers 124 3 miles by moderate riding at alternating angles The full grip levels are not achieved until the tires have been run in 7 PREPARING FOR USE 45
42. 172 Fuse 75011088015 p 172 e Ti j r AE the spare fuse in the fuse box so that it is available if needed Check that the power consumer is functioning properly Close the fuse box cover Position cover Mount and tighten screw O Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft a B00967 10 14 ELECTRICAL SYSTEM 14 7 Removing the headlight mask with the headlight 602577 10 Preparatory work Switch off all power consumers and switch off the engine Main work Duke Remove screws Duke R Remove screws 125 14 ELECTRICAL SYSTEM Fold the headlight mask forward Disconnect plug in connectors Remove the headlight mask 14 8 Refitting the headlight mask with the headlight Main work Connect plug in connectors 126 14 ELECTRICAL SYSTEM 127 Position the headlight mask Mount and tighten screws e Duke Position the headlight mask Mount and tighten screws e Guideline Screw headlight EJOT 2 Nm 1 5 Ibf ft Remaining screws chassis M5 5 Nm 3 7 Ibf ft Check that the lighting is functioning properly Duke R Guideline Screw headlight EJOT 2 Nm 1 5 Ibf ft Remaining screws chassis M5 5 Nm 3 7 Ibf ft Finishing work Check the headlight setting p 131 14 9 Changi
43. 37 Screw rocker arm shaft M6x30 12 Nm 8 9 Ibf ft Screw shift drum locating M6x30 10 Nm 7 4 Ibf ft Loctite 2437 Screw shift lever M6 14 Nm 10 3 Ibf ft Loctite 243 Screw starter motor M6x20 10 Nm 7 4 Ibf ft Loctite 243 22 TECHNICAL DATA 168 Screw stator M6 10 Nm 7 4 Ibf ft Loctite 243 Screw thermostat case M6x20 10 Nm 7 4 Ibf ft Loctite 243 Screw timing chain guide rail M6x30 10 Nm 7 4 Ibf ft Loctite 243 Screw timing chain tensioning rail M6x30 10 Nm 7 4 Ibf ft Loctite 2437 Screw valve cover M6 10 Nm 7 4 Ibf ft Screw water pump cover M6x30 10 Nm 7 4 Ibf ft Screw water pump impeller M6x15 10 Nm 7 4 Ibf ft Loctite 2437 Oil jet piston cooling M6x0 75 4 Nm 3 Ibf ft Loctite 2437 Screw plug crankshaft clamp M8 20 Nm 14 8 Ibf ft Stud exhaust flange M8 10 Nm 7 4 Ibf ft Loctite 243 Cylinder head screw M10 Tightening sequence Lubricated with engine oil Tighten diagonally beginning with the rear screw on the timing chain shaft Step 1 15 Nm 11 1 Ibf ft Step 2 30 Nm 22 1 Ibf ft Step 3 45 Nm 33 2 Ibf ft Step 4 60 Nm 44 3 Ibf ft Oil line for oil pressure sensor M10x1 10 Nm 7 4 Ibf ft Oil pressure sensor M10x1 10 Nm 7 4 Ibf ft Plug drain hole of water pump M10x1 15 Nm 11 1 Ibf ft Screw plug oil channel M10x1 15 Nm 11 1 Ibf ft Loctite 2437 Screw plug oil channel for oil r
44. 4 6 Changing the fuses of individual power consumers e Info The fuse box containing the fuses of individual power consumers is located on the right under the fuel tank Preparatory work Switch off all power consumers and switch off the engine Main work Remove screw Take off cover N B00967 10 14 ELECTRICAL SYSTEM 123 Open fuse box cover O Remove the defective fuse Guideline Fuse 1 10 A ignition combination instrument clock EFI control unit alarm sys tem optional Fuse 2 10 A ignition combination instrument EFI control unit Fuse 3 10 A fuel pump Fuse 4 10 A radiator fan Fuse 5 10 A horn brake light turn signal alarm system optional B00969 01 Fuse 6 15 A high beam low beam parking light tail light license plate lamp Fuse 7 10A for auxiliary equipment permanent positive Fuse 8 10A for auxiliary equipment accessories connected with ignition switch Fuse 9 10A ABS Fuse 10 not used Fuse SPARE 10 A 15 A spare fuses e Info A defective fuse is indicated by a burned out fuse wire 14 ELECTRICAL SYSTEM 124 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 75011088010 p
45. 92 mm 7 56 in Weight without fuel approx 149 5 kg 329 6 Ib Maximum permissible front axle load 150 kg 331 Ib Maximum permissible rear axle load 220 kg 485 Ib Maximum permissible overall weight 350 kg 772 Ib Battery CBTX9 BS Battery voltage 12 V Nominal capacity 8 Ah Maintenance free 22 TECHNICAL DATA 172 Fuse 58011109115 15A Fuse 58011109125 25A Fuse 58011109130 30A Fuse 75011088015 15A Fuse 75011088010 10A 22 5 Electrical system Headlight H4 socket P43t 12V 60 55 W Parking light W5W socket W2 1x9 5d 12V BW Instrument lights and indicator lamps LED Turn signal Duke RY10W socket BAU15s 12V 10 W Turn signal Duke R LED Brake tail light LED License plate lamp LED 22 6 Tires Front tires Rear tires 120 70 ZR 17 M C S8W TL Metzeler SPORTEC M7 RR 160 60 ZR 17 M C 69W TL Metzeler SPORTEC M7 RR Additional information is available in the Service section under http www ktm com 22 TECHNICAL DATA 173 22 1 Fork 22 7 1 Duke Fork part number 05 18 7L 19 Fork WP Suspension Up Side Down 4357 Spring rate Medium standard 6 0 N mm 34 3 Ib in Fork length 816 mm 32 13 in Fork oil per fork leg 480 ml 16 23 fl oz Fork oil SAE 4 4860116651 p 181 22 1 2 Duke R Fork part number 05 18 8M 11
46. Amm Y The TRIP 2 display is set to 0 0 401446 01 6 CONTROLS 6 11 13 TRIP F display 401447 01 37 If the fuel level drops to the reserve mark the display automatically changes to TRIP F and starts to count from 0 0 regardless of the previous display mode e Info The low fuel warning lamp lights up in parallel to the TRIP F display 401418 01 In display mode GEAr the gear currently engaged is displayed 6 CONTROLS 38 6 11 15 Coolant temperature indicator The temperature display consists of 12 bars The more bars that light up the hotter the coolant When the upper bar lights up all bars in the display begin to flash and the temper ature warning lamp lights up Possible states e Engine cold Up to four bars light up e Engine warm Five to eleven bars light up e Engine hot All twelve bars flash 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 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
47. Danger of accidents Unstable handling characteristics Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational and with a full tank driver and passenger with protective clothing and helmet baggage Warning Danger of accidents Unstable handling characteristics due to slipped baggage Check the way your baggage is fixed regularly Warning Danger of accidents Lack of roadworthiness After a fall check the vehicle as usual before preparing for use 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 8 RIDING INSTRUCTIONS 53 Note Engine failure Overheating of engine If the coolant temperature warning lamp lights up stop and switch off the engine Allow the engine to cool down and check the coolant level in the radiator and top up if necessary If you continue with the coolant temperature warning lamp alight you may have engine failure e Info If unusual noises arise during operation stop immediately park the vehicle properly and contact an authorized KTM workshop 99990 O0 401950 11 When conditions allow incline road situation etc you can shift into a higher gear Release the throttle while simultaneously pulling the clutch lever shift into the next gear re
48. M5x25 6 Nm 4 4 Ibf ft Screw cover plate for oil return line M5 6 Nm 4 4 Ibf ft Screw gear position sensor M5x16 5 Nm 3 7 Ibf ft Loctite 243 22 TECHNICAL DATA 167 Screw oil filter cover M5x16 6 Nm 4 4 Ibf ft Screw oil pump cover M5 6 Nm 4 4 Ibf ft Loctite 2437 Screw oil pump cover top M5 6 Nm 4 4 Ibf ft Loctite 2437 Chain securing guide M6 5 Nm 3 7 Ibf ft Cylinder head screw M6x25 10 Nm 7 4 Ibf ft Loctite 2437 Plug vacuum connection M6 10 Nm 7 4 Ibf ft Loctite 2437 Remaining screws engine M6 10 Nm 7 4 Ibf ft Screw alternator cover M6x25 10 Nm 7 4 Ibf ft Screw alternator cover chain shaft M6x25 10 Nm 7 4 Ibf ft Loctite 243 through hole Screw autodecompression M6 3 4 Nm 2 2 3 Ibf ft Loctite 243 Screw axial lock of camshaft M6 10 Nm 7 4 Ibf ft Loctite 243 Screw clutch cover M6 10 Nm 7 4 Ibf ft Screw clutch slave cylinder M6x20 10 Nm 7 4 Ibf ft Loctite 243 Screw clutch slave cylinder M6x35 10 Nm 7 4 Ibf ft Screw crankshaft position sensor M6x16 10 Nm 7 4 Ibf ft Loctite 2437 Screw cylinder M6 10 Nm 7 4 Ibf ft Loctite 2437 Screw engine case M6 10 Nm 7 4 Ibf ft Screw ignition coil M6 10 Nm 7 4 Ibf ft Screw locking lever M6x20 10 Nm 7 4 Ibf ft Loctite 2437 Screw oil pump cover bottom M6 10 Nm 7 4 Ibf ft Loctite 24
49. OWNER S MANUAL 2015 690 Duke EU 690 Duke CN 690 Duke R EU 690 Duke R AU 690 Duke R MY Art no 3213272en DEAR KTM CUSTOMER 1 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 20 Dealer s stamp Engine number p 22 Key number p 21 The Owner s Manual contained the latest information for this model series at the time of going to print Minor differences due to develop ments in design cannot be ruled out completely All specifications are non binding KTM Motorrad AG specifically reserves the right to modify or delete technical specifications prices col ors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local condi tions 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 Motorrad AG Mattighofen Austria All rights reserved Reproduction even in part as well as copying of all kinds
50. SYSTEM 137 15 4 Draining the coolant 4 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 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 immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swallowed 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 engine Remove screw Remove the radiator cap Completely drain the coolant Mount screw 1 with a new seal ring and tighten it Guideline Plug drain hole of water pump M10x1 15 Nm 11 1 Ibf ft K gt B00984 10 15 COOLING SYSTEM 138 15 5 Filling bleeding the cooling system 4 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 immedi
51. UUU SUBSTANCES AUXILIARY SUBSTANCES M K kk kk 18 19 20 21 22 23 24 25 STANDARDS INDEX 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 reaction e g of a work step or a function All work marked with this symbol requires specialist knowledge and technical understanding In the interest of your own safety have these jobs performed by an authorized KTM workshop There your motorcycle will be optimally cared for by specially trained experts using the specialist tools required f gt I 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 Name Identifies a protected name Brand Identifies a brand available on the open market 2 SAFETY ADVICE 8 2 1 Use definition intended e 0 KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race courses or offroad e Info The motorcycle is only authorized for operation on public roads in the homologated version A number of safety instructions need to be followed to operate the vehicle safely Therefore read this manual carefully The safety instruc tions are highlighted in the text and are referred to at the
52. W throttle actuator control IC stuck open Blink code of FI warning lamp MIL D 93 FI warning lamp MIL flashes 9x long 3x short Error level condition CPU mutual surveillance error Blink code of FI warning lamp MIL D 94 FI warning lamp MIL flashes 9x long 4x short Error level condition DBW stop function system error stop function A system error Blink code of FI warning lamp MIL D 95 FI warning lamp MIL flashes 9x long 5x short Error level condition DBW stop function system error stop function B system error 21 FLASH CODE 164 Blink code of Fl warning lamp MIL 96 FI warning lamp MIL flashes 9x long 6x short Error level condition System voltage input voltage too low System voltage input signal too high 22 TECHNICAL DATA 22 1 engine 165 Design 1 cylinder 4 stroke engine water cooled Displacement 690 cm3 42 11 cu in Stroke 84 5 mm 3 327 in Bore 102 mm 4 02 in Compression ratio 12 6 1 Control OHC 4 valves controlled via rocker arm chain drive Valve diameter intake 40 mm 1 57 in Valve diameter exhaust 34 mm 1 34 in Valve play cold 0 07 0 13 mm 0 0028 0 0051 in Crankshaft bearing 2 roller bearings Conrod bearing Needle bearing Piston pin bearing Piston pin with DLC coating Pistons Forged light alloy
53. a mnes RUD uer abate 126 remoVlng uua See See E e de HH pp 125 Headlight setting AGUSTIN ule coe f bebe eae Ve b Red 132 CHECKING it ae ia nom dk bate haere 131 Horn button 4 k n maye k kk Qene dak a 26 lenitionilock 2 L lt 5 yan a kk Soke an A a 29 Indicator lamps sa dla han sal dadin zik dka 31 Intended use llli 8 188 Key n mber esse A nee he wae Osa Ee RARE uses 21 Lioht SWitch i 2a Xena Dana A S eed 26 Loading the vehicle 0 0 cece eee eee eee 46 Main fuse CHANING zanate a Ked dee AeA a a e he oe ek ee 119 Motorcycle cleaning o a P EAE eet a n S 150 raising with the front wheel stand LL 74 raising with the rear wheel stand o o o 73 taking off of the front wheel stand 75 taking off of the rear wheel stand 73 Oil filter Changing sae wiki ts ub ea tA PR ah Boe RES li 144 Oil screens ClEANING asus Ga a dawa a a ed aon d da doe 144 Operating substances AV VI KIRR eee 13 Owner s Manual LL LA LL LS AV VII VIII KI KIRI ee ee 12 Parking 3 za xa ts Kall ure ust Ker usus aia mee kuran de o dis cs 56 Parking light bulb ChANBING aes Yad Caw a 129 INDEX Passenger footrests o ooo ooo eee ees 41 Passenger seat MOUNN uat s Seat ands se ld Baa S ns 76 neun Pc 75 Passenger seat cover mou hting x sod Pede HHHH 77 FEMOVING a senes ve WE Ie Re RUPEE ERE QURE aes 76 P
54. adiator M10x1 15 Nm 11 1 Ibf ft 22 TECHNICAL DATA 169 Screw unlocking of timing chain ten M10x1 10 Nm 7 4 Ibf ft sioner Spark plug outside M10x1 11 Nm 8 1 Ibf ft Spark plug inside M12x1 25 18 Nm 13 3 Ibf ft Coolant temperature sensor on cylinder M12x1 5 12 Nm 8 9 Ibf ft head Oil drain plug with magnet M12x1 5 20 Nm 14 8 Ibf ft Oil pressure regulator valve plug M12x1 5 20 Nm 14 8 Ibf ft Screw plug oil channel M14x1 5 15 Nm 11 1 Ibf ft Loctite 243 Engine case stud M16x1 5 25 Nm 18 4 Ibf ft Loctite 243 Rotor nut M18x1 5 100 Nm 73 8 Ibf ft Nut engine sprocket M20x1 5 80 Nm 59 Ibf ft Loctite 2437 Nut inner clutch hub M20x1 5 100 Nm 73 8 Ibf ft Loctite 243 Nut primary gear M20LHx1 5 90 Nm 66 4 Ibf ft Loctite 2437 Plug oil screen M20x1 5 15 Nm 11 1 Ibf ft Plug timing chain tensioner M20x1 5 25 Nm 18 4 Ibf ft Plug oil thermostat M24x1 5 15 Nm 11 1 Ibf ft Screw in alternator cover M24x1 5 8 Nm 5 9 Ibf ft 22 3 Capacities 22 3 4 Engine oil Engine oil 1 701 1 8 qt Engine oil SAE 10W 60 00062010035 p 180 Alternative engine oil Engine oil SAE 10W 50 p 181 22 TECHNICAL DATA 22 3 2 Coolant 170 Coolant 1 201 1 27 qt Coolant p 180 22 3 3 Fuel Total fuel tank capacity approx 14 3 7 US gal
55. aking efficiency due to damaged brake discs Always lay down the wheel in such a way that the brake discs are not dam aged Take the rear wheel out of the swingarm e Info Do not operate the foot brake lever when the rear wheel is removed 13 WHEELS TIRES 108 13 4 Installing the rear wheel 4 Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents No braking effect when operating the rear brake After installing the rear wheel always operate the foot brake until the pressure point is reached Main work Check the rear hub rubber dampers 4 p 110 Check the wheel bearing for damage and wear Ifthe wheel bearing is damaged or worn Replace the wheel bearing 4 Remove bushing Clean and grease the mating surfaces of the bushings and the shaft seal rings Long life grease p 183 Install the bushing 602566 10 Clean and grease the thread of the wheel spindle and nut Long life grease p 183 Clean the fixing locations on the brake caliper support and swingarm 13 WHEELS TIRES 109 Engage the counter bearing of brake caliper support o and the swingarm Lift the rear wheel into the swingarm position it and insert the wheel spindle Y The brake li
56. an 16 TUNING THE ENGINE 142 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 gear ing e Info I The range of adjustment is limited The shift lever must not come into contact with any other vehicle compo nents during the shift procedure Mount and tighten the screw Guideline Screw shift lever M6 14 Nm Loctite 243 10 3 Ibf ft Duke R Loosen nut O holding the threaded rod O e Info Nut o has a left handed thread Loosen nut e holding the threaded rod O CA Turn threaded rod 2 to adjust the shift lever ry S f M 602554 12 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 Tighten nut O holding the threaded rod O Guideline Shift rods nut M6 6 Nm 4 4 Ibf ft 16 TUNING THE ENGINE Tighten nut holding the threaded rod Guideline 143 Shift rods nut M6LH 6 Nm 4 4 Ibf ft 17 SERVICE WORK ON THE ENGINE 144 e Info The engine oil level must be checked at normal engine operating temperature Condition The engine is at operating temperature Stand the motorcycle upright on a horizontal surface Check the engine oil level e Info After switching off the engine wait one minute before che
57. anging 3 4 ende eae aa a ari 144 Engine oil level CHECKING ses be mm mm 144 Engine sprocket GHeECKING 2525 wait ete AS core ee eng ae a 83 ENVIO MON ae h A we kk ala a eee a 11 F FIQUI S ous ii ere ee he iR T Ud 14 Filler cap ClOSIMNG 2s Aas arse dt r Vp d 39 Opening sce ANO 38 Filling up TUO hz gutted doter en qe tr tatu MU pur m SLE Ere 58 Flash code nus e e peur PETES LG xir dik4 158 164 Foot brake lever nun si de Roh a UR aka d WE h etur 43 basic position adjusting llle 95 free travel checking KI KI KI KI KI K K KI KI K K KI K KIIR 94 Foot brake lever stub adjusting auper Tie e es 72 Footrests adjusting 5 213 emm mks E Vut eA 69 FORK qM PEUT 62 compression damping setting sn 62 rebound adjusting XY kk KK KRI RIK KIRR K KK KI KI 63 Fork part number LL LL LL A A SS KI KII KII KI KI ees 22 INDEX Front wheel installing ss 2 aw Ra ante a RAA Aut GR cue Re eee 103 removing usa denne Re dose a ek eee 102 Fuse individual power consumers changing 122 Fuses ABS changing an 244 Read waa X e de ee 121 Hand brake lever 2 00 24 basic position adjusting 0 000 cee eee eee 88 Handrails Ana a bake dih ak AR is 41 Headlight bulb CHANING 5 dono eken Gee ee CR IR tod pd tot 127 Headlight flasher switch o o o ooooo 27 Headlight mask with headlight INStANING save v
58. arking 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 autho rized KTM workshop will be glad to help 0 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 schedule Your authorized KTM workshop will be glad to help 12 BRAKE SYSTEM 92 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 attacks paint Use only clean brake fluid from a sealed container Preparatory work Check the front brake linings p 93 Main work Duke Move the brake fluid reservoir mounted on the handlebar to a horizon
59. bearing O Ifthe bearing is damaged or worn Replace the bearings 4 Check rubber dampers of the rear hub for damage and wear If the rubber dampers of the rear hub are damaged or worn Change all rubber dampers in the rear hub Lay the rear wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub To check play O hold the rear wheel tight and try to rotate the rear sprocket with your hand e Info Measure the play on the outside of the rear sprocket Play in rubber dampers rear wheel lt 5 mm lt 0 2 in 13 WHEELS TIRES 1n gt f play A is larger than the specified value Change all rubber dampers in the rear hub Finishing work Install the rear wheel A p 108 Take the motorcycle off of the rear wheel stand p 73 Check the chain tension p 79 13 6 Checking the tire condition Warning Danger of accidents Uncontrollable vehicle handling in the event of a flat tire Inthe interest of safety replace damaged or worn tires immediately Your authorized KTM workshop will be glad to help Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling characteristi
60. brake cleaner when necessary 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 The service life of the chain depends largely on its maintenance n Clean the chain regularly Rinse off loose dirt with a soft jet of water Remove old grease remains with chain cleaner Chain cleaner p 183 After drying apply chain spray Chain lube for road use p 183 400725 01 11 SERVICE WORK ON THE CHASSIS 79 11 11 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain is too taut the components of the secondary power transmission chain engine sprocket rear sprocket bearings in the transmission and in the rear wheel will be under additional load 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 11 SERVICE WORK ON THE CHASSIS 80 Lean the motorcycle on the side stand Shift gear to neutral Push the chain upwards near the vertical rib of the swingarm and measure the chain
61. c due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Warning Danger of accidents Reduced road grip with new tires P gt bb New tires have a smooth rolling surface and therefore cannot provide full road grip The entire rolling surface must be rough ened in the first 200 kilometers 124 3 miles by moderate riding at alternating angles The full grip levels are not achieved until the tires have been run in 13 WHEELS TIRES 112 e Info The type condition and air pressure of the tires all have a major impact on the riding behavior of the motorcycle Worn tires have a negative effect on riding behavior especially on wet surfaces Check the front and rear tires for cuts run in objects and other damage lt gt If the tires exhibit cuts run in objects or other damage Change the tires Check the depth of the tread e Info d I Note local national regulations concerning the minimum tread depth AQ 400602 10 Minimum tread depth 22mm gt 0 08 in Ifthe tread depth is less than the minimum permissible depth Change the tires Check the age of the tires e Info The tire s date of manufacture is usually part of the tire markings and is indi cated by the last four digits of the DOT marking The first two digits refer to the week of manufacture and last two digits
62. cking the level The engine oil must be between the lower and upper edge of the oil level viewer If the engine oil level is not at the specified level Add the engine oil p 149 Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations 17 SERVICE WORK ON THE ENGINE 145 e Info Drain the engine oil only when the engine is warm B00988 10 Main work Stand the motorcycle on its side stand on a horizontal surface M Place a suitable container under the engine Remove the oil drain plug o with the magnet and seal ring Completely drain the engine oil Thoroughly clean the oil drain plug with a magnet Remove screws O Remove the oil filter cover e 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 17 SERVICE WORK ON THE ENGINE 146 Remove screws Remove the oil filter cover with the O ring Pull oil filter out of the oil filter housing Circ
63. condition Throttle position sensor circuit A and B plausibility fault 21 FLASH CODE 162 Blink code of Fl warning lamp MIL a 85 FI warning lamp MIL flashes 8x long 5x short Error level condition Accelerator position sensor circuit A input signal too low Accelerator position sensor circuit A input signal too high Blink code of Fl warning lamp MIL a 86 FI warning lamp MIL flashes 8x long 6x short Error level condition Accelerator position sensor circuit B input signal too high Blink code of Fl warning lamp MIL 87 FI warning lamp MIL flashes 8x long 7x short Error level condition Accelerator position sensor circuit A and B plausibility fault Blink code of FI warning lamp MIL D 88 FI warning lamp MIL flashes 8x long 8x short Error level condition DBW throttle valve stuck open Blink code of FI warning lamp MIL D 89 FI warning lamp MIL flashes 8x long 9x short Error level condition Motor drive stuck stiff 21 FLASH CODE 163 Blink code of Fl warning lamp MIL D 90 FI warning lamp MIL flashes 9x long Error level condition Throttle actuator control motor relay stuck in INACTIVE DBW internal power relay active Blink code of Fl warning lamp MIL D 92 FI warning lamp MIL flashes 9x long 2x short Error level condition DB
64. e Check the way your baggage is fixed regularly Warning Danger of burns A hot exhaust system can burn baggage Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system If you carry any baggage make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu tion between the front and rear wheels Do not exceed the overall maximum permitted weight and the axle loads Guideline Maximum permissible overall weight 350 kg 772 Ib Maximum permissible front axle load 150 kg 331 Ib Maximum permissible rear axle load 220 kg 485 Ib 8 RIDING INSTRUCTIONS 8 1 Performing checks and vehicle care when preparing for use e Info Before each use check the state and roadworthiness of the vehicle Make sure that the vehicle is in perfect technical condition before use Check the engine oil level 7 p 144 Check the brake fluid level of the front brake p 90 Check the rear brake fluid level p 98 Check the front brake linings 7 p 93 Check the rear brake linings p 100 Check the brake system function Check the coolant level in the compensating tank p 135 Check the chain for dirt p 77 Check the chain tension p 79 Check the tire condition p 111 Check the tire pressure p 113 Check the settings of all controls
65. e battery to avoid damage to the onboard electron ics 14 ELECTRICAL SYSTEM M00672 10 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 rest potential and start potential of the battery and to test the alternator With this device you cannot overcharge the battery e Info Never remove lid O Switch off the battery charger after charging and disconnect from the battery Guideline The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the motorcycle is not in use 3 months Connect the negative cable with the battery Finishing work Mount the passenger seat p 76 Set the clock p 34 14 ELECTRICAL SYSTEM 119 14 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 The main fuse is under the passenger seat Preparatory work Switch off all power consumers and switch off the engine Remove the passenger seat p 75 p Main work Remove protection caps O 14 ELECTRICAL SYSTEM 120 Remove the faulty main fuse e Info A defect
66. e 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 144 18 CLEANING CARE 150 18 1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high pressure cleaning equipment When cleaning the vehicle with a pressure cleaner do not point the water jet directly onto electrical components connectors cables bearings etc Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component Excessive pres sure can cause malfunctions or destroy these parts 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 If you clean the motorcycle regularly its value and appearance will be maintained over a long period Avoid direct sunshine on the motorcycle during cleaning Seal the exhaust system to keep water out N First remove coarse dirt particles with a gentle spray of water ETT m Spray very dirty areas with a normal motorcycle cleaner and then clean with a brush Motorcycle cleaner p 183 e Info I Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the vehicle with
67. e 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 per tain to the disposal of an end of life motorcycle Your authorized KTM dealer will be glad to advise you 2 SAFETY ADVICE 12 29 OwmwrsMamad 000 0 It is important that you read this Owner s Manual carefully and completely before making your first trip The Owner s Manual contains use ful information and many tips on how to operate handle and maintain your motorcycle Only then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it as needed If you would like to know more about the vehicle or have questions on the material you read please contact an authorized KTM dealer The Owner s Manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold 3 IMPORTANT NOTES 13 The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer s Service amp Warranty Booklet and in the KTM Dealer net otherwi
68. eck the brake system and do not continue riding Your authorized KTM workshop will be glad to help 12 A A BRAKE SYSTEM 99 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 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 attacks paint Use only clean brake fluid from a sealed container Preparatory work Check the rear brake linings p 100 12 BRAKE SYSTEM 100 Main work Stand the vehicle upright Remove screw cap 1 with the washer and membrane O Add brake fluid to the MAX mark Brake fluid DOT 4 DOT 5 1 p 180 Mount the screw
69. ed The engine races and the rear wheel can lock up Warning Danger of accidents Malfunctions caused by incorrect ignition key position Do not change the ignition key position during a journey Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle Make all adjustments when the vehicle is at a standstill Warning Risk of injury Falling off of the passenger The passenger must be seated properly on the passenger seat and hold on to the front rider or the grab handles The feet must be positioned on the passenger footrests Note the regulations governing the minimum age of passengers Warning Danger of accidents Danger of accidents caused by dangerous driving Comply with traffic regulations and ride defensively and foresightedly to detect sources of danger early on 8 A A Note RIDING INSTRUCTIONS 52 Warning Danger of accidents Reduced road grip with cold tires On every journey take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured Warning Danger of accidents Reduced road grip with new tires New tires have a smooth rolling surface and therefore cannot provide full road grip The entire rolling surface must be rough ened in the first 200 kilometers 124 3 miles by moderate riding at alternating angles The full grip levels are not achieved until the tires have been run in Warning
70. en the vehicle is switched on again The ABS warning lamp goes out when you start off Button o can be used to switch ABS off manually see Starting Adjusting the basic position of the hand brake lever 602570 11 Duke Adjust the basic position of the hand brake lever to your hand size by turning adjusting wheel O e Info Push the hand brake lever forward and turn the adjusting wheel Do not make any adjustments while riding 12 BRAKE SYSTEM 602552 11 12 3 Checking the brake discs 89 Duke R Adjust the basic position of the hand brake lever to your hand size by turning adjusting wheel e Info Push the hand brake lever forward and turn the adjusting wheel Do not make any adjustments while riding 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 a 100135 10 Check the thickness of the front and rear brake discs in several places to ensure that it conforms to measurement O e Info Wear reduces the thickness of the brake disc at the contact surface O of the brake disc Brake discs wear limit Front 4 2 mm 0 165 in Rear 4 5 mm 0 177 in Ifthe brake disc thickness is less than the specified value 12 BRAKE SYSTEM 90 Replace the brake disc Check the front and rear
71. eral forces Warning Danger of accidents Vehicle rollover Itis not always possible to prevent vehicle rollover in extreme riding situations e g luggage loaded with a high center of gravity varying road surfaces steep descents full braking without disengaging the gear Adapt your riding style to the road conditions and your riding ability The ABS operates with two independent brake circuits front and rear brakes During nor mal operation the brake system operates like a conventional brake system without ABS When the ABS control unit detects a locking tendency in a wheel ABS begins regulating the brake pressure The regulating process causes a slight pulsing of the hand and foot brake levers 12 BRAKE SYSTEM 12 2 88 ABS warning lamp e must light up after the ignition is switched on and go out after start ing off If it does not go out after starting off or if it lights up while riding this indicates a fault in the ABS system In this case the ABS is no longer enabled and the wheels may lock during braking The brake system itself stays functional only ABS control is not avail able The ABS warning lamp may also light up if the rotating speeds of the front and rear wheels differ greatly under extreme riding conditions for example when making wheelies or if the rear wheel spins This causes the ABS to switch off To reenable the ABS the vehicle must be stopped and the ignition switched off The ABS is reenabled wh
72. f accidents Locking of the wheels due to braking action of the engine Pull the clutch during emergency braking full brake application and when braking on a slippery surface When braking release the throttle and apply the front and rear brakes at the same time Info e When ABS is active you can achieve maximum braking power even on low grip surfaces such as sandy wet or slippery terrain without locking of the tires Warning A Danger of accidents Road grip is reduced when braking with the motorcycle at an angle or on a laterally inclined surface Braking should be completed before you enter into a bend Braking should always be completed before you go into a bend Change down to a lower gear appropriate to your road speed 8 RIDING INSTRUCTIONS 56 On long downhill stretches use the braking effect of the engine Change down one or two gears but do not over rev the engine As a result you will have to apply the brakes far less frequently and the brake system will not overheat 8 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 If you leave the vehicle lock the steering and remove the ignition key Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch hot components such as exhaust syste
73. g system 00 The water pump in the engine forces the coolant to flow The pressure in the cooling system resulting from heat is regulated by a valve in the radia tor cap The heat expansion causes the surplus coolant to flow into the compensating tank O When the temperature falls this surplus coolant is sucked back into the cooling system This permits the specified coolant temperature without causing any malfunctions 125 C 257 F Cooling takes place by means of the air stream and a radiator fan O which is controlled by a thermoswitch The lower the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect 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 case of scalding rinse immediately with lukewarm water 15 COOLING SYSTEM 134 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 immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swallowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out
74. gine Remove the passenger seat p 75 b Main work Disconnect negative cable 1 from the battery 14 ELECTRICAL SYSTEM 115 Remove positive terminal cover Disconnect positive cable from the battery Detach rubber band Pull the battery up and out of the battery holder Main work Position the battery in the battery holder Battery CBTX9 BS p 171 Y The battery terminals face in the direction of travel Attach rubber band Connect positive cable to the battery Guideline Screw battery terminal M6 2 Nm 1 5 Ibf ft Mount positive terminal cover 14 ELECTRICAL SYSTEM 116 nena t Connect negative cable o to the battery DER Guideline Screw battery terminal M6 2 Nm 1 5 Ibf ft y MO0669 11 Finishing work Mount the passenger seat p 76 Set the clock p 34 14 3 Recharging the battery a 0 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 physician Warn
75. he SET button to set the minute Keep the MODE button and the SET button pressed simultaneously X The time is set km h 308 O0 FAB 401444 01 6 11 10 ODO display In the ODO display mode the total distance traveled is shown in kilometers or miles tT e Info LJ This value is retained even if the battery is disconnected and or the fuse blows km h 308 O0 FAB 401444 01 6 11 11 Setting resetting display TRIP 1 e Info The TRIP 1 trip counter is always running and counts up to 999 9 The trip counter can be used to measure the distance covered during trips or between two refueling stops After the value 999 9 is reached the trip counter starts at 0 0 again 6 CONTROLS 36 Switch on the ignition by turning the ignition key to the position Press the MODE button repeatedly until the TRIP 1 mode is active Keep the SET button pressed Y The TRIP 1 display is set to 0 0 401445 01 6 11 12 Setting resetting display TRIP 2 Info The TRIP 2 trip counter is always running and counts up to 999 9 The trip counter can be used to measure the distance covered during trips or between two refueling stops After the value 999 9 is reached the trip counter starts at 0 0 again HUS e UH Switch on the ignition by turning the ignition key to the position O Press the MODE button repeatedly until the TRIP 2 mode is active Keep the SET button pressed
76. he specified standards see specifications on the container and that possess the corresponding properties Fully synthetic engine oil Recommended supplier Motorex Power Synt 4T Standard classification SAE p 185 SAE 4 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding proper ties 23 SUBSTANCES 182 Standard classification ISO VG 15 Guideline Use only hydraulic oil that complies with the specified standard see specifications on the container and that possesses the corre sponding properties Recommended supplier Motorex Hydraulic Fluid 75 Standard classification SAE p 185 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding proper ties 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 24 AUXILIARY SUBSTANCES 18 wo Recommended supplier Motorex Chain Clean Guideline Recommended supplier Motorex Chainlube Road Recommended supplier Motorex
77. igh heat or with a heavy load 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 disassem ble 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 4 1 VIEW OF VEHICLE View of vehicle front left side example M00653 10 4 VIEW OF VEHICLE Clutch lever p 24 Seat Passenger seat Handrails p 41 Seat lock p 40 Engine number p 22 Shift lever p 42 QO NI n om A WwW N Side stand p 43 4 4 2 VIEW OF VEHICLE View of vehicle rear right side example M00654 10 4 VIEW OF VEHICLE 19 Tool set p 40
78. ing 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 authorized KTM dealer or dispose of it at a collection point for used batteries 14 ELECTRICAL SYSTEM 117 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 Even when there is no load on the battery it discharges steadily The charging level and the method of charging are very important for the service life of the battery Rapid recharging with a high charging current shortens the battery s service life If the charging current charging voltage or charging time is exceeded electrolyte escapes through the safety valves This reduces the battery capacity 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 sulfate destroying the battery The battery is maintenance free i e the acid level does not have to be checked Preparatory work Switch off all power consumers and switch off the engine Remove the passenger seat p 75 Disconnect the negative cable of th
79. is 11 6 10 Ignition steering lOCK E 29 2 9 Owner s Manual 0 cccccecececcccccececececececeeeeeas 12 6 11 Combination instrument UU 29 3 IMPORTANT NOTES ooccccncnncnccnnnccncnnnnnccnncnnnncnonnnnnncnonons 13 GLITI A t cebat ke ev ehe enis 29 3 1 Guarantee warranty A E 13 6 11 2 Function buttons kh b ll kk 30 3 2 Operating and auxiliary substances 13 6 T1 3 TaChOMeter ss eee Pec fir endete es 30 3 3 Spare parts accessories ccccccconoconononnnnnonononononos 13 6 11 4 Combination instrument indicator lamps 31 3 4 SelVICe ode es e Po dtp th round ees 13 6 11 5 Display uie tee et genet SNN N N DD n edet 14 6 11 6 Speed display 3 6 Customer service cssee ees 14 6 11 7 Setting kilometers or miles As IEW OF VEHICLE ula san id 16 A A ie me eat te deae reet pedcs 4 1 View of vehicle front left side example 16 6 11 9 Setting thiecloCKs nie oett metre 34 4 2 View of vehicle rear right side example 18 6 11 10 ODO display 5 SERIAL NUMBERS die bar einen l WA yak sik bate ul lue bet 20 6 11 11 Setting resetting display TRIP 1 35 5 1 Chassis number yx s k blla kal n ker leba hani aken d kan ei 20 6 11 12 Setting resetting display TRIP 36 Da SEype dabel eee A DD n 20 6 11 13 TRIP F display 5 3 Key MUMBO Ps 2 5 cc conden eroe tee eroe Pet Ver Ae Ku n 21 6 141 14 GEA
80. ition of 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 over heating Adjust the free travel on foot brake lever according to specifications Duke Disconnect spring Q Remove screw Q Loosen nut and turn it back with ball joint until the maximum amount of free travel is reached To adjust the basic position of the foot brake lever to individual requirements loosen nut and turn screw accordingly MN cos 17 10 e Info mM The range of adjustment is limited 12 BRAKE SYSTEM 96 Turn ball joint 5 as required until free travel A is reached If necessary adjust the basic position of the foot brake lever Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Hold screw e and tighten nut e Guideline Remaining nuts chassis M6 10 Nm 7 4 Ibf ft Hold ball joint and tighten nut Guideline Mount and tighten screw Q Guideline Screw ball joint of push M6 10 Nm Loctite 2437 rod on foot brake cylinder 7 4 Ibf ft Attach spring O Duke R Disconnect spring O Loosen nut 2 and screw in push rod until you have maximum free travel 12 BRAKE SYSTEM 97 To adjust the basic position of the foot brake lever to individual require
81. ive fuse is indicated by a burned out fuse wire O A reserve fuse is located in the starter relay Install a new main fuse Fuse 58011109130 p 172 e Tip Insert a new replacement fuse into the starter relay to have it available when needed Mount protection caps O Finishing work Mount the passenger seat p 76 Set the clock p 34 14 ELECTRICAL SYSTEM 121 14 5 Changing the ABS fuses 0 Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never bypass or repair fuses Info Two fuses for the ABS are located under the passenger seat These fuses protect the return pump and the hydraulic unit of the ABS The third fuse which protects the ABS control unit is located in the fuse box Preparatory work Switch off all power consumers and switch off the engine Remove the passenger seat p 75 To change the fuse of the ABS hydraulic unit Remove the protection cap and fuse Insert a new fuse Fuse 58011109115 p 172 Mount the protection cover 14 ELECTRICAL SYSTEM 122 To change the fuse of the ABS return pump Remove the protection cap and fuse O Insert a new fuse Fuse 58011109125 p 172 Mount the protection cover Finishing work Mount the passenger seat p 76 1
82. ive to reference marks O The Info tions Tighten nuts Tighten nut Guideline e I The upper part of the chain must be taut Chain wear is not always even Repeat this measurement at different chain posi Make sure that chain adjusters o are fitted correctly on adjusting screws e Nut rear wheel spindle M25x1 5 90 Nm 66 4 Ibf ft 11 SERVICE WORK ON THE CHASSIS 83 11 13 Checking the chain rear sprocket and engine sprocket 100132 10 Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the power set 4 Info The engine sprocket rear sprocket and chain should always be replaced together 11 SERVICE WORK ON THE CHASSIS 84 9 iE o 0 2 3 1 O OKO O 16 17 18 700152 01 Shift gear to neutral Pull the lower chain section with specified weight O Guideline Weight of chain wear measurement 15 kg 33 Ib Measure the distance o of 18 chain links in the lower chain section e Info Chain wear is not always even Repeat this measurement at different chain posi tions Maximum distance at the longest 272 mm 10 71 in chain section Ifthe distance o is greater than the specified measurement Replace the chain 4 e Info When the chain is replaced the rear sprocket and engine sprocke
83. kshop will be glad to help Applying the brakes 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 Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Failure of brake system 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 Longer stopping distance due to higher overall weight Take the longer stopping distance into account when carrying a passenger and baggage 8 A A RIDING INSTRUCTIONS 55 Warning Danger of accidents Delayed brake action on salted roads There may be salt deposits on the brake discs In order to restore the normal braking efficiency you will need to remove the deposits from the discs by carefully applying the brakes Warning Danger of accidents Greater stopping distance due to ABS Braking should be appropriate to the driving situation and the road conditions Warning Danger of accidents Very forceful braking can cause the wheels to block ABS must be switched on to be effective Warning Danger o
84. lamp MIL D 39 FI warning lamp MIL flashes 3x long 9x short Error level condition Ignition coil 2 cylinder 1 circuit fault Blink code of FI warning lamp MIL D 41 FI warning lamp MIL flashes 4x long 1x short Error level condition Fuel pump relay short circuit to ground or open circuit Fuel pump relay input signal too high 21 FLASH CODE 161 Blink code of Fl warning lamp MIL D 45 FI warning lamp MIL flashes 4x long 5x short Error level condition Lambda sensor heater cylinder 1 sensor 1 short circuit to ground or open circuit Lambda sensor heater cylinder 1 sensor 1 input signal too high Blink code of Fl warning lamp MIL a 65 FI warning lamp MIL flashes 6x long 5x short Error level condition E2PROM error Blink code of Fl warning lamp MIL D 82 FI warning lamp MIL flashes 8x long 2x short Error level condition Throttle position sensor circuit A input signal too high Throttle position sensor circuit A input signal too low Blink code of FI warning lamp MIL D 83 FI warning lamp MIL flashes 8x long 3x short Error level condition Throttle position sensor circuit B input signal too low Throttle position sensor circuit B input signal too high Blink code of Fl warning lamp MIL D 84 FI warning lamp MIL flashes 8x long 4x short Error level
85. lease the clutch lever and open the throttle e Info You can see the positions of the 6 forward gears in the figure The neutral or idle position is between the first and second gears First gear is used for starting off or for steep inclines The operating temperature is reached when 5 bars of the temperature indicator light up After reaching maximum speed by fully opening the throttle grip turn the throttle back so it is open This will barely reduce the speed but fuel consumption will be consid erably lower Accelerate only up to a speed suitable for the road surface and weather conditions Par ticularly in bends do not shift and accelerate very carefully To shift down brake if necessary and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again RIDING INSTRUCTIONS 54 If the engine stalls e g at a crossroads just pull the clutch lever and press the elec tric starter button You do not have to shift into neutral Switch off the engine if you expect to be standing for a long time Ifthe Fl warning lamp MIL lights up during a trip stop immediately When you shift to neutral the Fl warning lamp MIL starts to flash e Info From the flash rhythm you can deduce a two digit number the so called blink code The blink code tells you which component is affected by a fault Your authorized KTM wor
86. lip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing area Insert the oil filter Oil the O rings of the oil filter covers Mount oil filter covers e and Q Mount and tighten the screws Guideline Screw oil filter cover M5x16 6 Nm 4 4 Ibf ft Remove screw plug 8 with oil screen 9 and the O rings Completely drain the remaining engine oil Thoroughly clean the parts and sealing area 17 SERVICE WORK ON THE ENGINE 147 Remove screw plug with oil screen 11 and the O rings Completely drain the remaining engine oil Thoroughly clean the parts and sealing area Position the oil screen with the O rings Mount and tighten screw plug with the O ring Guideline Plug oil screen M20x1 5 15 Nm 11 1 Ibf ft Position the oil screen with the O rings Mount and tighten screw plug with the O ring Guideline Plug oil screen M20x1 5 15 Nm 11 1 Ibf ft Mount and tighten the oil drain plug with magnet and seal ring B00994 10 17 SERVICE WORK ON THE ENGINE 148 Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 Ibf ft e Info Too little engine oil or poor quality engine oil results in premature wear to the engine Remove the oil filler plug with the O ring from the clutch cover and fill up with engine oil E
87. load 10 clicks Spring preload Comfort 11 mm 0 43 in Standard 11 mm 0 43 in Sport 11 mm 0 43 in Full payload 11 mm 0 43 in Spring rate Soft 70 N mm 400 Ib in Medium standard 75 N mm 428 Ib in Spring length 185 mm 7 28 in Gas pressure 10 bar 145 psi Static sag 25 mm 0 98 in Riding sag 60 65 mm 2 36 2 56 in Fitted length 370 mm 14 57 in 22 TECHNICAL DATA 176 Shock absorber fluid Shock absorber fluid SAE 2 5 5018075151 p 182 22 9 Chassis tightening torques Screw combination instrument EJOT 1 Nm 0 7 Ibf ft Screw headlight EJOT 2 Nm 1 5 Ibf ft Screw headlight mask EJOT 1 Nm 0 7 Ibf ft Screw side stand switch MA 2 Nm 1 5 Ibf ft Loctite 243 Remaining screws chassis M5 5 Nm 3 7 Ibf ft Retaining clamp brake line M5 3 Nm 2 2 Ibf ft Screw air filter box M5 3 Nm 2 2 Ibf ft Screw cable on starter motor M5 3 Nm 2 2 Ibf ft Screw foot brake lever stub Duke M5 6 Nm 4 4 Ibf ft Loctite 243 Screw fuel level sensor M5 3 Nm 2 2 Ibf ft Screw fuel pump M5 4 Nm 3 Ibf ft Screw heat guard Duke M5 5 Nm 3 7 Ibf ft Loctite 2437 Screw light switch mount and emer M5 3 5 Nm 2 58 Ibf ft gency OFF switch Screw plastic clamp of brake line on M5 2 Nm 1 5 Ibf ft x fork leg Screw pressure regulator
88. locked with the ignition key The tool set is located under the passenger seat B00929 10 6 CONTROLS 41 6 46 Handrails The handrails O are used for moving the motorcycle around When you have a passenger the passenger can hold on the handrails during the journey The passenger footrests can be folded up and down Possible states e Passenger footrests folded up For operation without a passenger e Passenger footrests folded down For operation with a passenger 6 CONTROLS 42 618 Shiftlever 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 6 CONTROLS 43 Foot brake lever is located in front of the right footrest The rear brake is engaged with the foot brake lever 402177 10 The side stand is located on the left side of the vehicle The side stand is used for parking the motorcycle e Info The side stand must be folded up during motorcycle use The side stand is coupled with the safety starting system see the riding instruc tions Possible states e Side stand folded out The vehicle can be supported on the side stand The safety 402029 10 f starting system is active e Side stand folded in This position is mandatory when riding the motorcycle The safety
89. ltage 4 Check the quiescent current 4 Combination instrument shows nothing on the display Fuse 1 or 2 blown Change the fuses of p 122 Set the clock p individual power consumers 34 21 FLASH CODE 158 Blink code of Fl warning lamp MIL a 02 FI warning lamp MIL flashes 2x short Error level condition Crankshaft position sensor circuit fault Blink code of Fl warning lamp MIL a 09 FI warning lamp MIL flashes 9x short Error level condition Manifold absolute pressure sensor cylinder 1 input signal too low Manifold absolute pressure sensor cylinder 1 input signal too high Blink code of Fl warning lamp MIL D 12 FI warning lamp MIL flashes 1x long 2x short Error level condition Engine coolant temperature sensor input signal too low Engine coolant temperature sensor input signal too high Blink code of FI warning lamp MIL D 13 FI warning lamp MIL flashes 1x long 3x short Error level condition Intake air temperature sensor input signal too low Intake air temperature sensor input signal too high Blink code of Fl warning lamp MIL D 14 FI warning lamp MIL flashes 1x long 4x short Error level condition Ambient air pressure sensor input signal too low Ambient air pressure sensor input signal too high 21 FLASH CODE 159 Bli
90. m 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 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 8 RIDING INSTRUCTIONS 57 Brake the motorcycle Shift gear to neutral Switch off the ignition by turning the ignition key to the position amp e info I If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock power continues to flow to most power consumers and the battery will discharge You should therefore always switch off the engine with the ignition key the emergency OFF switch is intended for emergencies only Park the motorcycle on a firm surface Swing the side stand forward with your foot as far as it will go and lean the vehicle on it
91. m corresponds to the circumference of the 17 front wheel with a series pro duction tire The display then changes to the last selected mode 6 CONTROLS 6 11 6 Speed display 4 l LAR 308 ool FAB 401443 10 6 11 7 Setting kilometers or miles e Iinfo The speed 1 is shown in kilometers per hour km h or in miles per hour mph If you change the unit the value ODO is retained and converted accordingly Making the setting according to the country 33 Condition The motorcycle is stationary 6 CONTROLS 308 oll FAB 401444 01 6 11 8 Time z l Vafa 388 O0 FAB O 401443 11 6 11 9 Setting the clock 34 Switch on the ignition by turning the ignition key to the position Press the MODE button repeatedly until the ODO mode is active Keep the MODE button pressed until the display mode changes from km h to mph or from mph to km h The time is shown in area 1 of the display e Info After reconnecting the battery or changing the fuse the time must be reset Condition The motorcycle is stationary 6 CONTROLS 35 Switch on the ignition by turning the ignition key to the position Press the MODE button repeatedly until the ODO mode is active Keep the MODE button and the SET button pressed simultaneously Y The time display begins to flash Press the MODE button to set the hour Press t
92. ments loosen nut and turn screw O accordingly e Info The range of adjustment is limited Turn push rod e accordingly until you have free travel O If necessary adjust the basic position of the foot brake lever Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Hold screw o and tighten nut O Guideline Remaining nuts chassis M6 10 Nm 7 4 Ibf ft Hold push rod e and tighten nut O Guideline Nut push rod foot brake lever M6 6 Nm 4 4 Ibf ft Attach spring O 12 BRAKE SYSTEM 98 Warning Danger of accidents Failure of the brake system 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 If the fluid level reaches the MIN marking Add rear brake fluid 4 p 98 Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Ch
93. ndicator lamps The indicator lamps offer additional information about the operating state of the motorcy cle Possible states The turn signal indicator light flashes green simultaneously with the turn signal The turn signal is switched on The idling speed indicator lamp lights up green The transmission is shifted to idle The high beam indicator lamp lights up blue The high beam is switched on The temperature warning lamp lights up red The coolant temperature has reached a critical value The low fuel warning lamp lights up orange The fuel level has reached the reserve mark The display switches to TRIP F The oil pressure warning lamp lights up red The oil pressure is too low FI warning lamp MIL lights up flashes yellow The OBD on board diagno sis has detected an emission or safety critical error The battery warning lamp lights up red The voltage in the vehicle system is too low ABS warning lamp lights up flashes yellow Status or error messages relat ing to ABS antilock brake system C5 G9 D amp f 2 6 CONTROLS 6 11 5 Display GEEE ZBBSHSHS 400836 01 BD L EnbEh 400881 01 32 When you switch on the ignition all display segments light up for one second as a function check LEnGth Following the display function check the LEnGth wheel circumference is shown for one sec ond e Info 1870 m
94. ng the headlight bulb Check that the lighting is functioning properly Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting 14 ELECTRICAL SYSTEM B00973 10 B00974 10 Preparatory work Switch off all power consumers and switch off the engine Remove the headlight mask with the headlight p 125 Main work Unplug connector Remove protection cap Detach retaining clamp O Remove bulb Position the new bulb in the headlight housing 128 Headlight H4 socket P43t p 172 Y Tabs engage in the recesses Attach retaining clamp e 14 ELECTRICAL SYSTEM 129 Mount protection cap O Plug in connector O B00973 10 Finishing work Refit the headlight mask with the headlight p 126 Check the headlight setting p 131 14 10 Changing the parking light bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off all power consumers and switch off the engine Remove the headlight mask with the headlight p 125 14 ELECTRICAL SYSTEM 130 Main work Pull cable slee
95. ngine oil 1 70 1 8 qt Engine oil SAE 10W 60 00062010035 p 180 Alternative engine Engine oil oil SAE 10W 50 7 p 181 Install and tighten the oil filler plug with the O ring 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 Start the engine and check that it is oil tight Finishing work Check the engine oil level p 144 17 SERVICE WORK ON THE ENGINE 149 17 3 X Adding engine oil e Info Too little engine oil or poor quality engine oil results in premature wear to the engine Main work Remove the oil filler plug with the O ring from the clutch cover and fill up with engine oil Engine oil SAE 10W 60 00062010035 p 180 Engine oil SAE 10W 50 p 181 e Info For optimal performance of the engine oil do not mix different types of engine oil If appropriate change the engine oil Install and tighten the oil filler plug 1 with the O ring 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 th
96. nings are correctly positioned Place the chain on the sprocket Position chain adjuster O Mount nut O but do not tighten it yet e Info Mount the left and right chain adjusters in the same position Make sure that chain adjusters 2 are fitted correctly on the adjusting screws Tighten nut Guideline In order for the rear wheel to be correctly aligned the markings on the left and right chain adjusters must be in the same position relative to the reference marks O Nut rear wheel spindle M25x1 5 90 Nm 66 4 Ibf ft Position wheel speed sensor in the drill hole Mount and tighten screw M00668 10 Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft 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 Take the motorcycle off of the rear wheel stand p 73 Check the chain tension p 79 13 WHEELS TIRES 110 135 Checking the rear hub rubber dampers A 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 rear sprocket carrier and the rear hub will be damaged Preparatory work Raise the motorcycle with the rear wheel stand p 73 Remove the rear wheel 4 p 106 Main work Check
97. nk code of Fl warning lamp MIL a 15 FI warning lamp MIL flashes 1x long 5x short Error level condition Rollover sensor input signal too low Rollover sensor input signal too high Blink code of Fl warning lamp MIL a 17 FI warning lamp MIL flashes 1x long 7x short Error level condition Lambda sensor cylinder 1 sensor 1 circuit fault Blink code of Fl warning lamp MIL D 22 FI warning lamp MIL flashes 2x long 2x short Error level condition Gear position sensor circuit fault Blink code of FI warning lamp MIL D 24 FI warning lamp MIL flashes 2x long 4x short Error level condition System voltage circuit fault Blink code of FI warning lamp MIL D 25 FI warning lamp MIL flashes 2x long 5x short Error level condition Side stand switch circuit fault 21 FLASH CODE 160 Blink code of Fl warning lamp MIL D 27 FI warning lamp MIL flashes 2x long 7x short Error level condition Sensor supply voltage circuit fault Blink code of FI warning lamp MIL e 33 FI warning lamp MIL flashes 3x long 3x short Error level condition Injector cylinder 1 circuit fault Blink code of Fl warning lamp MIL a 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
98. oad 10 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce damping during slow to normal compression 10 7 Adjusting the rebound damping of the shock absorber Duke R Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help 10 TUNING THE CHASSIS 67 Turn adjusting screw clockwise up to the last perceptible click Turn counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks 602574 10 LEGES Full payload 10 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce damping 10 8 Adjusting the spring preload of the shock absorber 4 Warning A Danger of accidents Modifications to the suspension settings can seriously alter the vehicle s ride behavior Following modifications ride slowly at first to get the feel of the new ride behavior Info The spring preload defines the initial situation of the spring process on the shock absorber The best spring preload setting is achieved when it is set for the weight of the rider and that of any baggage and a passenger thus ensuring an ideal compromise between maneuverability and
99. of reach of children Condition The engine is cold Preparatory work Stand the motorcycle upright on a horizontal surface Main work Remove radiator cap o and plug 2 from the compensating tank Check the coolant antifreeze 25 45 C 13 49 F Ifthe coolant antifreeze does not meet specifications Correct the coolant antifreeze Check the coolant level in the compensating tank The coolant level must be at marking MIN If the coolant in the compensating tank is not at the required level but the tank is not empty Add coolant to the MIN marking Coolant p 180 If there is no coolant in the compensating tank Check the cooling system for leaks 4 15 COOLING SYSTEM 135 e Info Do not start up the motorcycle Fill bleed the cooling system amp p 138 Mount cap of the compensating tank Check the coolant level in the radiator The radiator must be completely filled Ifthe coolant level does not meet specifications Correct the coolant level and find out the cause of the loss Coolant p 180 Ifyou had to add more coolant than the specified amount gt 0 50 gt 0 53 qt Fill bleed the cooling system amp p 138 Mount radiator cap 15 3 Checking the coolant level in the compensating tank Warning Danger of scalding During motorc
100. oooo oooo 85 Combination instrument CLOCK SEA tu oes doa Gly Ss 34 coolant temperature indicator o o o ooooooo 38 display ss messes uis E n cots GER MEE 32 f nctlon buttons ox uo DAR naw a WARA Hb Kir 30 GEAT di DIAy stato dade hs ker dda t pnt bere 37 indicator lamps eec l k Ok dk VA a S REM 31 kilometers or miles setting eres 33 INDEX ODO display ccs dE REPRE SE wale 35 OVENVIEW oo aie ee Sada e adnexa em gore uh 29 speed display gt sd ow w d A phat 33 tachometer lt 3 3 5 2 205 os Minden ut xm d d n dew ee 30 Hines A Le ue e Eis ES 34 TRIP 1 display setting resetting o o 35 TRIP 2 display setting resetting less 36 TRIP F display i iue a eer ee ee ed 37 Coolant dralnlng lt a Eda hth oe eee tada 4s 137 Coolant level CHECKINS dco dor RA Ed A 133 compensating tank checking llle 135 Cooling System 5 dio uel else alte OR E l la e e 133 filling bleeding leen 138 Customer service llle 14 E Electric starter button llle 28 Emergency OFF switch o o o ooooooo 28 Engine MANABI s as tm on cate b ay te Oe TEA ds ao roe S Gur 45 Engine characteristics Settlhg au e Sues oy J J J MD MM MD JJ i IMIMINNn E NNE EW 140 Engine number 0 0 0 cece ee lez kl k 22 Engine oil adding Seve harder ew AS wy eS u 149 187 ch
101. r display sida eei i Sb tee al n k 5 4 Engine number iukk kk 22 6 11 15 Coolant temperature indicator 38 5 5 Fork part number leke 22 6 12 Opening the filler cap 38 TABLE OF CONTENTS 10 6 13 Closing the filler cap E 39 6 14 Seat lock ss 2 kin kan k uen eee eee eis 40 6 I5 A eode debt tiep Meza S 40 6 16 Handralls a oes dek NAN cae 41 6 17 Passenger footrests hA h hK i E 41 6 18 Shift lever scores iyya si al ici 42 6 19 Foot brake lever ins 43 6 20 Side staM incitar ia 43 PREPARING POR USE epi kenare orti ki s ke eur lah dan 44 7 1 Advice on first use oocccooccncocccncoconcnocnncnncnonnnnncnnons 44 7 2 Running in the engine cccccccsseceeeeeeeeeeeeeaees 45 7 3 Loading the vehicle hb hA k E E 46 RIDING INSTRUCTIONS Mek 48 8 1 Performing checks and vehicle care when preparing for TT S l sisya aa daka y kan k l oce essi va aero ha 48 8 2 ria RT 49 8 3 Starting Off RM b1 8 4 Shifting riding ALLE 51 8 5 Applying the brakesS kk 54 8 6 Stopping Parking cscs acc yan kl ota vea dada 56 8 7 TANS PO Eivissa leka hare Kas ade e De ERR Da 57 8 8 Reta 58 SERVICE SCHEDULE occccnnccnnnncnnnncnnnncnncnocnnnnncncnnnnnnnnnns 60 9 1 Service SChedule cocccccccncccoccononcnccncnncononononnnnnns 60 TUNING THE CHASSIS c occccccccccnncnonocnnnonnnccncnnnononononcnnnns 62 10 1 Fork shock absorber Duke R
102. r hub rubber dampers 4 110 13 6 Checking the tire condition 111 13 7 Checking the tire pressure ssssesse 113 ELECTRICAL SYSTEM consta ias 114 14 1 Removing the battery amp EU 114 14 2 Installing the battery amp 115 15 16 17 14 3 Recharging the battery amp UU 14 4 Changing the main fUSE occccoccnccccnnconcnononcnnnnos 14 5 Changing the ABS fuses occccoccccccccnconcnononcncnnos 14 6 Changing the fuses of individual power COISUITIeIS ossa rrr 14 7 Removing the headlight mask with the head hln yk A ede teu moc Sata 14 8 Refitting the headlight mask with the headlight otro deterret Perse gir edis 14 9 Changing the headlight bulb 14 10 Changing the parking light bulb 14 11 Changing the turn signal bulb Duke 14 12 Checking the headlight setting 14 13 Adjusting the headlight range COOLING SYSTEM suscrita 15 1 Cooling system ooccccoccncnncncconnnccnnnnnoninononinonons 15 2 Checking the antifreeze and coolant level 15 3 Checking the coolant level in the compensating i i deep PES 15 4 Draining the coolant A EE 15 5 Filling bleeding the cooling system TUNING THE ENGINE rra eo e eth au nere ne 16 1 Setting the engine characteristics
103. ratory work Switch off the ignition by turning the ignition key to the position amp Remove the passenger seat p 75 Main work Pull off the Map Select switch with holder 1 from the retaining bracket Pull the Map Select switch out of the holder Turn the adjusting wheel until the desired number is aligned with marking e Set the Map Select switch to Soft Set the adjusting wheel to position 1 Y Soft Homologated performance with very gentle response Set the Map Select switch to Advanced Set the adjusting wheel to position 2 Y Advanced Homologated performance with very direct response Set the Map Select switch to Standard Set the adjusting wheel to position 3 4 5 6 7 8 9 or 0 X Standard Homologated performance with balanced response Position the Map Select switch in the holder Push the Map Select switch with the holder into the retaining bracket 16 TUNING THE ENGINE 141 Finishing work Mount the passenger seat 7 p 76 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 39 0 79 in edge of boot If the distance does not meet specifications Adjust the basic position of the shift lever A p 141 400692 10 Duke Remove screw 1 and take off shift lever e E C DL R
104. reparing for use advice on first use JA kk kk KK KK KIR K KK KIR ee 44 aflef StOra p z A Aza o e t a bak d Qa dinanan c b a e ld 154 checks and vehicle care when preparing for use 48 Protective clothing o o o ooooooo oo 11 R Rear hub rubber dampers CHECKING uus uode een awe ea ata 110 Rear sprocket Checking sena iea eek ea a eu 83 Rear wheel Installing av c n ae din woe ode made oe EE del Kak SA 108 FOMOVING uic We cp irte apts A n laya awk dik n 106 ill 00 ii mo 51 starting Oni e eR teen mf Soa edt i KEH AE g des aes Gee ce kurey EL UR 51 S Safe operation ALL LL AV KV KII KI KI KI KIRI K K KI IK 10 Seat lockK oa ayan bd uec Qa ye need le d le te d dia c n d W n 40 SOIVICO SS an se tet A A bek n au nt Ak Dana ada 13 189 Service schedule LL LL LL A A KK KK KK KIRR KI KI oo 60 61 Shift T VON su kk a imr Atal k OR a bada W eid tay AOE 42 basic position adjusting o ooooooooo KK 141 basic position checking KIRI eee 141 Shiftifig D AK RA E ee ka a eee AU 51 Shock absorber i n axa din k a kla ek a ja y 62 compression damping general o o oo oooo 64 compression damping high speed adjusting 64 compression damping low speed adjusting 65 rebound damping adjusting 0000 eee 66 spring preload adjusting o o o oooooooooo 67 Shock absorber part number
105. rson Among those acts presumed to constitute tampering are the acts listed below 2 SAFETY ADVICE 10 1 Removal or puncturing of the main silencer baffles header pipes or any other components which conduct exhaust gases 2 Removal or puncturing of parts of the intake system 3 Lack of proper maintenance 4 Replacing moving part of the vehicle or parts of the exhaust or intake system with parts other than those specified by the manufac turer 2 5 Safe operation Danger Al 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 Al 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 ts intended use and in a safe and environmentally compatible manner An appropriate driver s
106. s be the basis of your own personal chassis adaptation Do not change the adjustments at random or by more than 40 since otherwise the riding characteristics could deteriorate particularly at high speeds 10 2 Adjusting the compression damping of the fork Duke R e Info The hydraulic compression damping determines the fork suspension behavior Turn the white adjusting screw 1 all the way clockwise Info Adjusting screw 1 is located at the upper end of the left fork leg The compression damping is located in the left fork leg COMP white adjusting screw The rebound damping is located in the right fork leg REB red adjusting screw NA RIA e 2 760 0210 Turn counterclockwise by the number of clicks corresponding to the fork type 2 10 TUNING THE CHASSIS 63 Guideline Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce damping 10 3 Adjusting the rebound damping of the fork Duke R e Info The hydraulic rebound damping determines the fork suspension behavior 602572 10 Turn the red adjusting screw o all the way clockwise Info e Adjusting screw 1 is located at the upper end of the right fork leg The rebound damping is located in the right fork leg REB red adjusting screw The compres
107. se all warranty claims will be void No warranty claims can be considered 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 of components 3 IMPORTANT NOTES 14 Use of the vehicle under difficult conditions such in rain h
108. shop overload In this way you can avoid long workshop waiting times at the start of the new season N X ur Oyr 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 183 Refuel p 58 Clean the motorcycle p 150 Change the engine oil and filter clean the oil screens 4 9 p 144 Check the antifreeze and coolant level p 133 Check the tire pressure p 113 Remove the battery 4 p 114 Recharge the battery 4 7 p 116 Guideline Storage temperature of battery without 0 35 C 32 95 F direct sunshine Store the vehicle in a dry location that is not subject to large fluctuations in tempera ture e Info KTM recommends jacking up the motorcycle Raise the motorcycle with the rear wheel stand p 73 19 STORAGE 19 2 Preparing for use after storage 2 N 401059 01 154 Raise the motorcycle with the front wheel stand p 74 Cover the motorcycle with a porous sheet or blanket Info e Do not use non porous materials since they prevent humidity from escaping thus causing corrosion Avoid running the engine for a short time only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust Take the mo
109. sion UUUU U UUjUU ULj E TABLE OF CONTENTS 12 13 14 11 13 Checking the chain rear sprocket and engine SDIOCKGL irae cee tne asndat secteur crees eate px EUR 83 11 14 Adjusting the basic position of the clutch lever 85 11 15 Checking rectifying the fluid level of the hydraulic cl tch uices cinere cien eno enira 86 BRAKE SYSTEM iiec oce Go c Reset sitive indica cles 87 12 1 ABS antilock brake system eeeeeeees 87 12 2 Adjusting the basic position of the hand brake ym 88 12 3 Checking the brake discs cccccseeeeeseeeeeeeeeees 89 12 4 Checking the brake fluid level of the front brake 90 12 5 Adding front brake fluid X 91 12 6 Checking the front brake linings 93 12 7 Checking the free travel of foot brake lever 94 12 8 Adjusting the basic position of the foot brake O 95 12 9 Checking rear brake fluid level 98 12 10 Adding rear brake fluid A E 98 12 11 Checking the rear brake linings 100 WHEELS TIRES oct eren id 102 13 1 Removing the front wheel A 102 13 2 Installing the front wheel amp UUEUUUEUUUUUULUEU 103 13 3 Removing the rear wheel X U E U E LL EEEE 106 13 4 Installing the rear wheel A j j j jj 108 13 5 Checking the rea
110. sion damping is located in the left fork leg COMP white adjusting screw Turn counterclockwise by the number of clicks corresponding to the fork type 10 TUNING THE CHASSIS 64 Guideline Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Full payload 7 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce damping 10 4 Compression damping of the shock absorber Duke R 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 when riding over an asphalt edge the rear wheel suspension compresses 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 10 5 Adjusting the high speed compression damping of the shock absorber Duke R Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be
111. stability Preparatory work Duke R Raise the motorcycle with the work stand 10 TUNING THE CHASSIS Remove the main silencer 4 Remove the shock absorber 4 Main work Duke Adjust the spring preload by turning adjustment unit O Guideline 68 Spring preload Standard 4 clicks Hook wrench T106S e Iinfo The spring preload can be set to 10 different positions Duke R Release retaining ring O Hook wrench T106S Turn adjusting ring e to adjust the spring preload Guideline Spring preload Comfort 11 mm 0 43 in 602558 10 Standard 11 mm 0 43 in Sport 11 mm 0 43 in Full payload 11 mm 0 43 in Tighten retaining ring Q 10 TUNING THE CHASSIS Finishing work Duke R Install the shock absorber 4 Install the main silencer 4 Remove the motorcycle from the work stand Install the footrest bracket 10 9 Adjusting the footrests 69 e Info The operations on the footrest brackets are the same for the left and right sides Remove lock ring Remove the pin of the rider footrest Take off the rider footrest with the spring C00329 10 10 TUNING THE CHASSIS X Remove screws Guideline Mount and tighten screws e Adjust the footrest bracket to the desired position 70 Screw front footrest bracket M8 25 Nm 18 4
112. t should also be changed New chains wear out faster on old worn sprockets For safety reasons the chain has no chain joint 11 SERVICE WORK ON THE CHASSIS Guideline Check the chain sliding guard for wear If drill hole becomes visible on the chain sliding guard in area O Replace the chain sliding guard 4 Check that the chain sliding guard is firmly seated Ifthe chain sliding guard is loose Tighten the screw of the chain sliding guard 85 B00942 1 0 Screw chain sliding guard M6 10 Nm 7 4 Ibf ft Loctite 243 11 14 Adjusting the basic position of the clutch lever Info e I 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 force Do not make any adjustments while riding screw A M00656 13 Adjust the basic position of the clutch lever to your hand size by turning adjusting 11 SERVICE WORK ON THE CHASSIS 86 11 15 Checking rectifying the fluid level of the hydraulic clutch Info e The fluid level rises with increasing wear of the clutch facing discs Do not use brake fluid Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi
113. t to one side e Info Do not pull the hand brake lever while the brake caliper is removed Duke R Remove screw and pull wheel speed sensor out of the hole Remove screws and spacers Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc Pull the brake caliper carefully back from the brake disc and hang it to one side e Info Do not pull the hand brake lever while the brake caliper is removed 13 WHEELS TIRES 103 Loosen screw 5 by several rotations Release screws O Press on screw 5 to push the wheel spindle out of the axle clamp Remove screw Warning Danger of accidents Reduced braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not dam 602546 10 aged Hold the front wheel and remove the wheel spindle Take the front wheel out of the fork 13 2 Installing the front wheel A 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 Check the wheel bearing for damage and wear Ifthe wheel bearing is damaged or worn Replace the wheel bearing 4 Clean grease and mount the left and right spacers and the shaft seal rings Long life grease p 183 3602547 01
114. tal position Remove screws Remove cover with membrane O Add brake fluid to level Guideline Level brake fluid level below con 5 mm 0 2 in tainer rim N B00948 10 Brake fluid DOT 4 DOT 5 1 p 180 Position the cover with the membrane Mount and tighten the screws e Info Clean up overflowed or spilt brake fluid immediately with water 12 BRAKE SYSTEM 93 Duke R Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover e with membrane O Add brake fluid to the MAX mark Brake fluid DOT 4 DOT 5 1 p 180 Position the cover with the membrane Mount and tighten the screws 602576 10 e Info Clean up overflowed or spilt brake fluid immediately with water 12 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 regularly 12 BRAKE SYSTEM 94 Check the brake linings for minimum thickness O
115. that it is locked correctly by pulling up Finally check that the passenger seat is correctly mounted 11 7 Removing the passenger seat cover Duke R Insert the ignition key in seat lock O and turn it clockwise Raise the rear of the passenger seat cover push it toward the rear and remove it upward Remove the ignition key from the seat lock 11 SERVICE WORK ON THE CHASSIS 7 Warning Danger of accidents Accident risk caused by the presence of a passenger f the passenger seat cover is mounted the vehicle is not suitable for transporting a passenger Do not ride with a passenger Hook catches o of the passenger seat cover onto the storage compartment lower the rear and simultaneously push forward Press down the passenger seat cover until it clicks into place Finally check that the passenger seat cover is correctly mounted Check the chain for heavy soiling lt gt Ifthe chain is very dirty Clean the chain p 78 400678 01 11 SERVICE WORK ON THE CHASSIS 78 11 10 Cleaning the chain A A Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with
116. throttle If you open the throttle during the start ing procedure fuel is not injected by the engine management system and the engine cannot start Press the starter for a maximum of 5 seconds Wait for a least 5 seconds before trying again This motorcycle is equipped with a safety starting system You can only start the engine if the transmission is in neutral or if the clutch lever is pulled when a gear is engaged If the side stand is folded out and you shift into gear and release the clutch lever the engine stops Take the weight off the side stand and swing it back up with your foot as far as it will go Switching off ABS KTM recommends riding with ABS at all times However situations may arise in which ABS is not advantageous Condition Vehicle stationary engine running Press the button for 3 5 seconds Y The ABS warning lamp starts flashing ABS is deactivated 8 8 3 RIDING INSTRUCTIONS 51 Starting off Pull the clutch lever engage 1st gear release the clutch lever slowly and simultaneously open the throttle carefully 8 4 Shifting riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control Avoid abrupt load alterations and sudden braking actions and adapt your speed to the road conditions Warning Danger of accidents If you change down at high engine speed the rear wheel can lock up Do not change into a low gear at high engine spe
117. ting When starting DO NOT open the throttle Carry out the start procedure p 49 Engine has too little power Air filter is very dirty Remove the air filter Install the air filter Fuel filter is very dirty Check the fuel pressure Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool A Map Select switch incorrectly adjusted Set the engine characteristics 7 p 140 20 TROUBLESHOOTING 156 Faults Engine overheats Possible cause Too little coolant in cooling system Action Check the cooling system for leakage Check the coolant level in the compensating tank p 135 Radiator fins very dirty Clean radiator fins Foam formation in cooling system Drain the coolant 4 p 137 Fill bleed the cooling system 4 p 138 Buckled or damaged radiator hose Change the radiator hose 4 Thermostat is faulty Check the thermostat 4 Fuse 4 blown Change the fuses of individual power consumers p 122 Defect in radiator fan system Check the radiator fan system FI warning lamp MIL lights flashes Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool N The idle indicator lamp does not light up when the transmission is in neutral Gear position sensor not programmed Read out the fault memory using the KTM diag nostics tool
118. tion Remove screws O Remove cover with membrane O Check the fluid level Fluid level below container rim 4 mm 0 16 in If the coolant level does not meet specifications Correct the fluid level of the hydraulic clutch Hydraulic fluid 15 p 182 Position the cover with the membrane Mount and tighten the screws 12 BRAKE SYSTEM 12 1 ABS antilock brake system i e N 401417 10 87 The ABS unit which consists of a hydraulic unit ABS control unit and return pump is installed under the seat A wheel speed sensor is located at the front and rear wheels Warning Danger of accidents Functional limitations of the ABS The rear wheel may only be spun with the front brake applied burn out if the ABS is switched off Ifthe vehicle has been modified such as shortened or lengthened spring deflec tions different rim diameters different tires the wrong tire air pressure differ ent brake linings etc the ABS will not function optimally Optimal function ing of the ABS is only ensured if the brake system only contains spare parts and tires that have been approved and or recommended by KTM Service work and repairs must be performed properly Your authorized KTM workshop will be glad to help The ABS is a safety system that prevents locking of the wheels when driving straight ahead without the influence of lat
119. torcycle off of the front wheel stand p 75 Take the motorcycle off of the rear wheel stand p 73 Recharge the battery 4 p 116 Install the battery 4 p 115 Set the clock p 34 Perform checks and vehicle care when preparing for use p 48 Take a test ride 20 TROUBLESHOOTING 155 Faults Engine does not crank when the elec tric starter button is pressed Possible cause Operating error Action Carry out the start procedure p 49 The battery is discharged Recharge the battery amp p 116 Check the quiescent current 4 Fuse 1 2 or 3 blown Change the fuses of individual power consumers p 122 Main fuse burned out Change the main fuse p 119 No ground connection present Check the ground connection Engine turns only if the clutch lever is drawn The vehicle is in gear Shift gear to neutral The vehicle is in gear and the side stand is folded out Shift gear to neutral Engine turns but does not start Operating error Carry out the start procedure p 49 Fuse 3 blown Change the fuses of individual power consumers 7 p 122 The plug in connection of the fuel hose connection is not connected Connect the plug in connection of the fuel line Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool A Throttle opened while star
120. ve 1 and the socket of parking light e carefully out of the housing O O Remove the bulb Position a new light bulb in the socket Parking light W5W socket W2 1x9 5d p 172 Carefully position socket with the bulb in the housing Mount cable sleeve B00975 10 Finishing work Refit the headlight mask with the headlight p 126 Check the headlight setting p 131 14 11 Changing the turn signal bulb Duke Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting 14 ELECTRICAL SYSTEM M00678 10 14 12 Checking the headlight setting A rA 400726 10 131 Remove the screw on the rear of the turn signal housing Remove turn signal glass O Press the bulb carefully into the socket turn it counterclockwise by about 30 and pull it out of the socket e Info Do not touch the reflector with your fingers and keep it free from grease Press the new bulb carefully into the socket and turn it clockwise all the way Turn signal RY1OW socket BAU15s p 172 Position the turn signal glass Insert the screw and turn it counterclockwise first until it engages in the thread with a light jerk Tighten the screw slightly Check that the turn signal s
121. water 401061 01 first If the vehicle was operated in road salt clean it with cold water Warm water enhances the corrosive effects of salt 18 CLEANING CARE 151 After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the closure of the exhaust system Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake sys tem Clean or dry a dirty 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 After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 78 Treat bare metal parts except for brake discs and exhaust system with anti corrosion materials Preserving materials for paints metal and rubber p 184 Treat all painted parts with a mild paint polish Perfect Finish and high gloss polish for paints p 184 e Info Do not polish parts that were matte when delivered as this would strongly impair the material quality Treat all plastic parts and powder coated parts with a mild cleaning and care agent Special cleaner for glossy and matte paint finishes metal and plastic surfaces p 184 18 CLEANING CARE 152 Lubricate the ignition steering lock
122. 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 not be sufficient This will result in problems with the fuel system Your authorized KTM workshop will be glad to help 8 RIDING INSTRUCTIONS 59 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 cap p 38 Fill the fuel tank with fuel up to the lower edge O of the filler neck Total fuel tank 14 I 3 7 US gal Super unleaded ROZ 95 RON 95 PON capacity approx 91 p 182 Close the filler cap p 39 B00935 10 Press the SET button 2 for two seconds v The low fuel warning lamp switches off TRIP F is set to 0 and the previous dis play mode appears e Info If you do not press the SET button e the reset takes place automatically after about three minutes 401429 10 9 SERVICE SCHEDULE 9 1 Service schedule 60 Every 20 000 km 12 428 mi
123. ycle 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 case of scalding rinse immediately with lukewarm water 15 COOLING SYSTEM 136 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 immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swallowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Condition The engine is cold The radiator is completely full Preparatory work Park the motorcycle on a horizontal surface Main work Check the coolant level in the compensating tank O The coolant level must be at marking MIN Ifthe coolant in the compensating tank is not at the required level but the tank is not empty Remove the compensating tank cap Add coolant to the MIN marking Coolant p 180 Mount the cap of the compensating tank If there is no coolant in the compensating tank Check the cooling system for leaks 4 e Info Do not start up the motorcycle Fill bleed the cooling system amp p 138 15 COOLING
124. ystem is functioning properly Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight Make another mark at a distance B under the first mark Guideline Distance 5 cm 2 in Position the vehicle vertically at a distance O in front of the wall and switch on the low beam Guideline Distance 5 m 16 ft The rider with luggage and passenger if applicable now mounts the motorcycle 14 ELECTRICAL SYSTEM 132 Check the headlight setting The light dark boundary must lie exactly on the lower mark when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applicable If the boundary between light and dark does not meet specifications Adjust the headlight range p 132 Preparatory work Check the headlight setting 7 p 131 Main work Adjust the beam distance of the headlight by turning screw O Guideline For a motorcycle with rider and with luggage and a passenger if applicable the light dark boundary must be exactly on the lower mark applied in Checking the headlight setting e Info Turn counterclockwise to increase the headlight range turn clockwise to reduce the headlight range If you have a payload you may have to correct the headlight range 15 COOLING SYSTEM 133 15 1 Coolin

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