OWNER'S MANUAL 2020

RC4 R
Art. no. 3214169en
 DEAR KTM CUSTOMER

Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art,
DEAR KTM CUSTOMER

sporty motorcycle that you will continue to enjoy for a long time if you maintain it properly. We wish you good and
safe riding at all times!

Enter the serial numbers of your vehicle below.

Vehicle identification number ( p. 12) Dealer's stamp

Engine number ( p. 12)

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

All specifications contained herein are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right
to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc.,
without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop produc-
tion of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from fig-
ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that
does not belong to the regular scope of supply.

© 2020 KTM Sportmotorcycle GmbH, Mattighofen Austria

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

ISO 9001(12 100 6061)

KTM applies quality assurance processes that lead to the highest possible product quality as
defined in the ISO 9001 international quality management standard.
Issued by: TÜV Management Service

KTM Sportmotorcycle GmbH

Stallhofnerstraße 3
5230 Mattighofen, Austria

This document is valid for the following models:

RC4 R (F8199T1)

*3214169en*
3214169en

01/2020
TABLE OF CONTENTS

6.19 Foot brake lever ............................... 19

TABLE OF CONTENTS

1 MEANS OF REPRESENTATION ...................... 5

6.20 Plug-in stand................................... 19
1.1 Symbols used .................................... 5
1.2 Formats used..................................... 5 7 COMBINATION INSTRUMENT ..................... 20

2 SAFETY ADVICE............................................ 6 7.1 Combination instrument ................... 20

2.1 Use definition – intended use.............. 6 8 PREPARING FOR USE................................. 24

2.2 Misuse.............................................. 6
8.1 Advice on preparing for first use ........ 24
2.3 Safety advice..................................... 6
8.2 Running in the engine ...................... 25
2.4 Degrees of risk and symbols ................ 6
8.3 Starting power of lithium-ion
2.5 Tampering warning............................. 7 batteries at low temperatures ............ 25
2.6 Safe operation ................................... 7
2.7 Protective clothing ............................. 7 9 RIDING INSTRUCTIONS.............................. 26
2.8 Work rules......................................... 8 9.1 Checks and maintenance measures
2.9 Environment...................................... 8 when preparing for use ..................... 26
2.10 Owner's Manual ................................. 8 9.2 Starting........................................... 26
9.3 Activating launch control .................. 27
3 IMPORTANT NOTES...................................... 9
9.4 Activating traction control ................. 28
3.1 Manufacturer and implied warranty...... 9 9.5 Starting off...................................... 28
3.2 Fuel, auxiliary substances ................... 9 9.6 Shifting, riding ................................ 28
3.3 Spare parts, accessories ..................... 9 9.7 Applying the brakes.......................... 29
3.4 Service ............................................. 9 9.8 Stopping, parking............................. 30
3.5 Figures ............................................. 9 9.9 Transporting .................................... 31
3.6 Customer service................................ 9 9.10 Refueling ........................................ 31
4 VIEW OF VEHICLE ...................................... 10 10 SERVICE SCHEDULE .................................. 33
4.1 View of vehicle, front left (example) ... 10 10.1 Additional information ...................... 33
4.2 View of vehicle, rear right 10.2 Service work .................................... 33
(example)........................................ 11
11 TUNING THE CHASSIS ............................... 35
5 SERIAL NUMBERS ..................................... 12
11.1 Adjusting the compression damping
5.1 Vehicle identification number............ 12 of the fork ....................................... 35
5.2 Engine number ................................ 12 11.2 Adjusting the rebound damping of
5.3 Fork article number.......................... 12 the fork........................................... 35
5.4 Shock absorber article number .......... 12 11.3 Adjusting the spring preload of the
fork ................................................ 36
6 CONTROLS................................................. 13
11.4 Adjusting the spring preload of the
6.1 Clutch lever..................................... 13 shock absorber ............................. 36
6.2 Hand brake lever.............................. 13 11.5 Compression damping of the shock
6.3 Throttle grip .................................... 13 absorber.......................................... 37
6.4 Switch-off button ............................. 13 11.6 Adjusting the high-speed
compression damping of the shock
6.5 Start button..................................... 14
absorber.......................................... 38
6.6 Tail light switch ............................... 14
11.7 Adjusting the low-speed
6.7 Quickshifter switch .......................... 14 compression damping of the shock
6.8 Combination switch.......................... 15 absorber.......................................... 38
6.9 Malfunction indicator lamp ............... 15 11.8 Adjusting the rebound damping of
6.10 Service hour counter ........................ 15 the shock absorber ........................... 39
6.11 Steering damper .............................. 16
12 SERVICE WORK ON THE CHASSIS............... 40
6.12 Quickshifter..................................... 16
6.13 Adjusting the steering damper........... 16 12.1 Raising the motorcycle with rear
6.14 Opening the fuel tank filler cap ......... 17 lifting gear ...................................... 40
6.15 Closing the fuel tank filler cap........... 17 12.2 Removing the rear of the motorcycle
6.16 Cold start button.............................. 18 from the lifting gear ......................... 40
6.17 Idle speed adjusting screw ................ 18 12.3 Lifting the motorcycle with the front
lifting gear ...................................... 40
6.18 Shift lever ....................................... 18

2
 TABLE OF CONTENTS

12.4 Taking the motorcycle off the front 12.44 Changing the hydraulic clutch
lifting gear ...................................... 41 fluid ............................................ 70
12.5 Raising the motorcycle with a lift 12.45 Adjusting the basic position of the
stand .............................................. 41 clutch lever ..................................... 72
12.6 Removing the motorcycle from the
13 BRAKE SYSTEM ......................................... 73
lift stand ......................................... 42
12.7 Removing the fork legs .................. 42 13.1 Checking the brake discs .................. 73
12.8 Installing the fork legs .................. 43 13.2 Checking the front brake fluid level ... 73
12.9 Removing the lower triple clamp .... 45 13.3 Adding front brake fluid ................ 74
12.10 Installing the lower triple clamp ..... 45 13.4 Checking the front brake linings ........ 75
12.11 Checking the steering head bearing 13.5 Changing the brake linings of the
play ................................................ 48 front brake ................................... 75
12.12 Adjusting the steering head bearing 13.6 Adjusting the basic position of the
play ............................................ 48 hand brake lever .............................. 78
12.13 Lubricating the steering head 13.7 Checking the rear brake fluid level..... 78
bearing ........................................ 49 13.8 Adding rear brake fluid ................. 78
12.14 Removing the shock absorber ........ 49 13.9 Checking the rear brake linings ......... 80
12.15 Installing the shock absorber ......... 51 13.10 Changing the rear brake linings ...... 80
12.16 Removing the front fender ................ 52 13.11 Adjusting the basic position of the
12.17 Installing the front fender ................. 53 foot brake lever................................ 82
12.18 Taking off the front rider's seat along 13.12 Checking the free travel of the foot
with the fuel tank cover ................. 53 brake lever ...................................... 83
12.19 Mounting the front rider's seat along 13.13 Adjusting the free travel of the foot
with the fuel tank cover .................... 54 brake lever ................................... 83
12.20 Removing the front spoiler ............ 54 13.14 Adjusting the foot brake lever
12.21 Fitting front spoiler .......................... 54 resistance ....................................... 84
12.22 Removing the tail section .............. 55
14 WHEELS, TIRES ......................................... 85
12.23 Installing the tail section ............... 55
12.24 Removing the trim along with the 14.1 Removing the front wheel .............. 85
front ............................................ 56 14.2 Installing the front wheel .............. 85
12.25 Installing the trim along with the 14.3 Removing the rear wheel ............... 86
front ............................................ 56 14.4 Installing the rear wheel ................ 86
12.26 Removing the air filter .................. 57 14.5 Checking the tire condition ............... 88
12.27 Cleaning the air filter and air filter 14.6 Checking tire pressure ...................... 89
box ............................................. 57
12.28 Installing the air filter ................... 58 15 ELECTRICAL SYSTEM ................................. 90
12.29 Checking for chain dirt 15.1 Removing the 12-V battery ............ 90
accumulation................................... 58 15.2 Installing the 12-V battery ............. 91
12.30 Cleaning the chain ........................... 59 15.3 Charging the 12-V battery ............. 91
12.31 Checking the chain tension ............... 59 15.4 Changing main fuse ......................... 93
12.32 Adjusting the chain tension............... 60 15.5 Changing the fuse of individual
12.33 Checking the chain, rear sprocket, power consumers ............................. 94
and engine sprocket ......................... 61 15.6 Diagnostics connector ...................... 95
12.34 Removing the main silencer .......... 62
12.35 Installing the main silencer ........... 63 16 COOLING SYSTEM ...................................... 96
12.36 Changing the glass fiber yarn filling 16.1 Cooling system ................................ 96
of the main silencer ...................... 64 16.2 Checking the antifreeze and coolant
12.37 Removing the fuel tank ................. 65 level ............................................... 96
12.38 Installing the fuel tank .................. 66 16.3 Checking the coolant level ................ 97
12.39 Checking the frame ...................... 68 16.4 Draining the coolant ..................... 97
12.40 Checking the link fork ................... 68 16.5 Refilling with coolant .................... 98
12.41 Checking the throttle cable routing .... 68 16.6 Changing the coolant........................ 99
12.42 Checking the rubber grips ................. 69
12.43 Checking/correcting the fluid level of 17 TUNING THE ENGINE............................... 101
hydraulic clutch............................... 69 17.1 Checking the throttle cable play ...... 101

3
TABLE OF CONTENTS

17.2 Adjusting the throttle cable 30 LIST OF SYMBOLS.................................... 143

play .......................................... 101
30.1 Yellow and orange symbols.............. 143
17.3 Adjusting the idle speed .............. 102
17.4 Teaching the throttle valve INDEX ............................................................. 144
position......................................... 103
17.5 Checking the basic position of the
shift lever...................................... 103
17.6 Adjusting the shift lever.................. 104
17.7 Adjusting the quickshifter ............... 105
18 SERVICE WORK ON THE ENGINE .............. 107
18.1 Changing the fuel screen ............. 107
18.2 Checking the engine oil level........... 108
18.3 Changing the engine oil and oil
filter, cleaning the oil screen ....... 109
18.4 Adding engine oil ........................... 111
19 CLEANING, CARE ..................................... 112
19.1 Cleaning the motorcycle ................. 112
20 STORAGE ................................................. 114
20.1 Storage ......................................... 114
20.2 Preparing for use after storage......... 115
21 TROUBLESHOOTING ................................ 116
22 BLINK CODE ............................................ 118
23 TECHNICAL DATA..................................... 120
23.1 Engine .......................................... 120
23.2 Engine tightening torques ............... 121
23.3 Capacities ..................................... 123
23.3.1 Engine oil ................................. 123
23.3.2 Coolant ..................................... 123
23.3.3 Fuel ......................................... 123
23.4 Chassis ......................................... 123
23.5 Electrical system............................ 124
23.6 Tires ............................................. 124
23.7 Fork.............................................. 124
23.8 Shock absorber .............................. 125
23.9 Chassis tightening torques .............. 125
24 WIRING DIAGRAM .................................... 128
24.1 Page 1 of 4 ................................... 128
24.2 Page 2 of 4 ................................... 130
24.3 Page 3 of 4 ................................... 132
24.4 Page 4 of 4 ................................... 134
25 SUBSTANCES .......................................... 136
26 AUXILIARY SUBSTANCES ......................... 138
27 STANDARDS ............................................ 140
28 INDEX OF SPECIAL TERMS ....................... 141
29 LIST OF ABBREVIATIONS.......................... 142

4
 MEANS OF REPRESENTATION 1

1.1 Symbols used

The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).

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

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

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

Indicates information with more details or tips.

Indicates the result of a testing step.

Indicates a voltage measurement.

Indicates a current measurement.

Indicates the end of an activity, including potential rework.

1.2 Formats used

The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.

Name® Indicates a protected name.

Brand™ Indicates a brand available on the open market.

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

5
2 SAFETY ADVICE

2.1 Use definition – intended use

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

Info
Only operate this vehicle in closed-off areas remote from public road traffic.

2.2 Misuse
The vehicle must only be used as intended.
Dangers can arise for people, property and the environment through use not as intended.
Any use of the vehicle beyond the intended and defined use constitutes misuse.
Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the
respective use.

2.3 Safety advice

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

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

2.4 Degrees of risk and symbols

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

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

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

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

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

6
 SAFETY ADVICE 2

2.5 Tampering warning

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

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

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

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

2.6 Safe operation

Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
– Do not operate the vehicle if you are physically or mentally impaired.

Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.

Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system
before the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.

Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a
safe and environmentally compatible manner.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.

2.7 Protective clothing

Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket
with protectors on all rides.
– Always wear protective clothing that is in good condition and meets the legal regulations.

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

7
2 SAFETY ADVICE

2.8 Work rules

Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models
with remote key) or the engine must be at a standstill (models without ignition lock or remote key).
Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered
using the number in parentheses. Example: bearing puller (15112017000)
During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts, seals,
sealing rings, O-rings, pins, and lock washers).
In the case of certain screws, a screw adhesive (e.g. Loctite®) is required. Observe the manufacturer's instruc-
tions.
If thread locker (e.g., Precote®) has already been applied to a new part, do not apply any additional thread locker.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged
or worn parts.
After completing a repair or service work, check the operating safety of the vehicle.

2.9 Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the
future of the motorcycle sport, make sure that you use your motorcycle legally, display environmental conscious-
ness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and
regulations of the respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no
legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad
to advise you.

2.10 Owner's Manual

It is important that you read this Owner's Manual carefully and completely before making your first trip. The Own-
er's Manual contains useful information and many tips on how to operate, handle, and service your motorcycle.
Only then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself
from injury.
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed.
If you would like to know more about the vehicle or have questions on the material you read, please contact an
authorized KTM dealer.
The Owner's Manual is an important component of the vehicle and must be handed over to the new owner if the
vehicle is sold.

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

8
 IMPORTANT NOTES 3

3.1 Manufacturer and implied warranty

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

3.2 Fuel, auxiliary substances

Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.

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

3.3 Spare parts, accessories

For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM
and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any
resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized KTM
dealer will be glad to advise you.

The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com

3.4 Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work
on the engine and chassis is properly carried out as described in the Owner's Manual. An incorrect suspension
setting can lead to damage and breakage of chassis components.
Use of the vehicle under difficult conditions, such as in heavy rain, intense heat or with a heavy payload, may
result in significantly increased wear of components such as the drive train, brake system, or suspension compo-
nents. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly,
you will ensure a much longer service life for your motorcycle.
The relevant mileage or time interval is whichever occurs first.

3.5 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not
always necessary to disassemble the component to perform the activity in question. Please follow the instructions
in the text.

3.6 Customer service

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

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

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

9
4 VIEW OF VEHICLE

4.1 View of vehicle, front left (example)

S03963-10

1 Clutch lever ( p. 13)

2 Fuel tank filler cap
3 Shift lever ( p. 18)

10
 VIEW OF VEHICLE 4

4.2 View of vehicle, rear right (example)

S03964-10

1 Switch-off button ( p. 13)

2 Combination switch ( p. 15)
3 Start button ( p. 14)
4 Hand brake lever ( p. 13)
5 Foot brake lever ( p. 19)

11
5 SERIAL NUMBERS

5.1 Vehicle identification number

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

S03965-10

5.2 Engine number

Engine number 1 is embossed on the left side of the engine
above the engine sprocket.

S03966-10

5.3 Fork article number

The fork article number 1 is stamped on the inside of the axle
clamp.

S03863-10

5.4 Shock absorber article number

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

S03864-10

12
 CONTROLS 6

6.1 Clutch lever

Clutch lever 1 is fitted on the handlebar on the left.

S03967-10

6.2 Hand brake lever

The front brake is engaged using the hand brake lever.
The hand brake lever 1is located on the right side of the han-
dlebar.

S03968-10

6.3 Throttle grip

The throttle grip 1 is fitted on the right side of the handlebar.

S03968-11

6.4 Switch-off button

Switch-off button 1 is fitted on the left side of the handlebar.
Possible states
• The switch-off button is in the basic position – In this
position, the ignition circuit is closed and the engine can be
started.
• The switch-off button is pressed – In this position, the igni-
tion circuit is interrupted, a running engine stops, and a non-
running engine will not start.

S03969-10

13
6 CONTROLS

6.5 Start button

Start button 1 is fitted on the right side of the handlebar.
Possible states
• The start button is in the basic position
• The start button is pressed – In this position, the starter
motor is actuated.

S03970-10

6.6 Tail light switch

Tail light switch 1 is located next to the combination instrument
on the right.
Possible states
Tail light off – The tail light switch is in position 0. In
this position, the tail light is switched off.
Tail light on – The tail light switch is in position 1. In
this position, the tail light is switched on.

S03985-10

6.7 Quickshifter switch

Quickshifter switch 1 is located next to the combination instru-
ment on the left.

Info
If you are not shifting and a misfire occurs while riding,
the quickshifter should be switched off until the cause is
identified and fixed.

Possible states
S03986-10
Quickshifter off – The quickshifter switch is in posi-
tion 0. In this position, the quickshifter is switched
off.
Quickshifter on – The quickshifter switch is in posi-
tion 1. In this position, the quickshifter is switched
on.

14
 CONTROLS 6

6.8 Combination switch

The combination switch is fitted on the left side of the handlebar.
Possible states
1 STANDARD – STANDARD mapping is activated when
LED 1 lights up.
1TC STANDARD with TC – STANDARD mapping with trac-
tion control is activated when LED 1 and TC light up.
2 ADVANCED – ADVANCED mapping is activated, when
LED 2 lights up.
2 TC ADVANCED with TC – ADVANCED mapping with trac-
tion control is activated when LED 2 and TC light up.
The engine characteristic can be changed using button MAP on the
combination switch.
The launch control and the traction control can also be activated
using the combination switch.

H02887-01

6.9 Malfunction indicator lamp

Possible states
Malfunction indicator lamp lights up/flashes orange
– The OBD has detected a malfunction in the vehicle
electronics.
Malfunction indicator lamp flashes orange rapidly
– Launch control is activated.

S03987-01

6.10 Service hour counter

Service hour counter 1is attached between the fuel tank and
the steering head.
It shows the total number of service hours of the engine.
The service hour counter begins counting when the engine is
started and stops when the engine is switched off.

Info
The value indicated by the service hour counter cannot be
cleared or adjusted.
S03988-10

15
6 CONTROLS

6.11 Steering damper

Steering damper 1 suppresses shocks to the steering arising
from acceleration on uneven ground at high speed or when the
load is temporarily taken from the front wheel.
The steering damper is adjusted to suit the riding style and the
road conditions. For high speeds, a setting with high damping can
be chosen to make the best possible use of the steering damper
function. In slow, tight bends, intensive damping can negatively
affect handling and steering precision, so the damping should be
set to low.
S03989-10

6.12 Quickshifter
Quickshifter 1 is located in the tail section of the motorcycle.

S04071-01

6.13 Adjusting the steering damper

Info
In contrast to other absorbing elements, the steering damper is adjusted with the absorbing element open.

– Turn adjusting screw 1 counterclockwise to the last

detectable click.
– Adjust the steering damper according to your riding style and
the road conditions by turning adjusting screw 1 clockwise.
Guideline
Steering damper adjustment 1 … 32 clicks
range
Standard 16 clicks
S03989-11
Do not change the adjustment of the steering damper during
the journey.
– After adjusting the steering damper, check the steering for
freedom of movement.
The handlebar can be moved from one stop to the other
without a locking tendency.

16
 CONTROLS 6

6.14 Opening the fuel tank filler cap

Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.

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

Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.

– Press in fuel tank quick release 1 and turn counterclockwise.

– Take off the fuel tank cover.

S03971-10

6.15 Closing the fuel tank filler cap

– Position the fuel tank cover.
Guideline
The fuel tank cover must not protrude.
– Turn fuel tank quick release 1 clockwise.

S03972-01

17
6 CONTROLS

6.16 Cold start button

The cold start button 1 is fitted to the bottom of the throttle
valve body.
The electronic fuel injection system extends the injection time if
the engine is cold and the ambient temperature is low. To help the
engine burn the increased fuel quantity, it must be supplied with
additional oxygen by pushing the cold start button.
After briefly opening up the throttle and then releasing the throttle
grip again, or turning the throttle grip towards the front, the cold
start button returns to its original position.
S03973-10

Info
Check whether the cold start button has returned to its
basic position.

Possible states
• The cold start button is activated – The cold start button is
pushed in all the way.
• The cold start button is deactivated – The cold start button is
in its basic position.

6.17 Idle speed adjusting screw

The idle setting of the throttle valve body substantially influences
the vehicle’s starting behavior, a stable idle speed, and the vehi-
cle’s response when the throttle is opened.
An engine with a correctly set idle speed is easier to start than an
engine with the idle speed set incorrectly.
The idle speed is adjusted using the idle speed adjusting
screw 1 .
Increase the idle speed by turning the idle speed adjusting screw
clockwise.
S03974-10 Decrease the idle speed by turning the idle speed adjusting screw
counterclockwise.

6.18 Shift lever

Shift lever 1 is located in front of the left footrest.

401950-10

18
 CONTROLS 6

The gear positions can be seen in the figure.

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

S03861-01

6.19 Foot brake lever

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

402177-10

6.20 Plug-in stand

The support for plug-in stand 1 is the left side of the wheel spin-
dle.
The plug-in stand is used to park the motorcycle.

Info
Remove the plug-in stand before riding.

H03892-10

19
7 COMBINATION INSTRUMENT

7.1 Combination instrument

S03977-01

20
 COMBINATION INSTRUMENT 7

The combination instrument is attached in front of the handlebar.

21
7 COMBINATION INSTRUMENT

S03978-01

22
 COMBINATION INSTRUMENT 7

The adjustment of the combination instrument is shown in the graphic.

23
8 PREPARING FOR USE

8.1 Advice on preparing for first use

Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
– Do not operate the vehicle if you are physically or mentally impaired.

Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket
with protectors on all rides.
– Always wear protective clothing that is in good condition and meets the legal regulations.

Warning
Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling charac-
teristic.
Different tire tread patterns can make the vehicle significantly more difficult to control.
– Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.

Warning
Danger of accidents An unadapted riding style impairs the handling characteristic.
– Adapt your riding speed to the road conditions and your riding ability.

Warning
Danger of accidents The vehicle is not designed to carry passengers.
– Do not ride with a passenger.

Warning
Danger of accidents The brake system fails in the event of overheating.
If the foot brake lever is not released, the brake linings drag continuously.
– Take your foot off the foot brake lever when you are not braking.

Warning
Danger of accidents Total weight and axle loads influence the handling characteristic.
– Do not exceed the maximum permissible overall weight or the axle loads.

Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running.
– Protect the vehicle against access by unauthorized persons.

Info
When using the motorcycle, remember that others may be disturbed by excessive noise.

– Ensure that the pre-sales inspection work has been carried out by an authorized KTM workshop.
The delivery certificate is transferred upon vehicle handover.
– Read the entire Owner's Manual before riding for the first time.
– Get to know the controls.
– Adjust basic position of the clutch lever. ( p. 72)
– Adjust basic position of the hand brake lever. ( p. 78)

24
 PREPARING FOR USE 8

– Adjust the basic position of the foot brake lever. ( p. 82)

– Adjust the shift lever. ( p. 104)
– Get used to the handling characteristic of the motorcycle on suitable terrain before undertaking a more chal-
lenging ride.

Info
This vehicle is not approved for use on public roads.

– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
– Do not carry the luggage.
– Do not exceed the maximum permissible weight and maximum permissible axle loads.
Guideline
Maximum permissible overall weight 190 kg (419 lb.)
Maximum permissible front axle load 93 kg (205 lb.)
Maximum permissible rear axle load 97 kg (214 lb.)
– Run the engine in. ( p. 25)

8.2 Running in the engine

– Do not exceed the specified engine speed and load during the running-in period.
Guideline
Maximum engine speed
During the first operating hour 7,000 rpm
Maximum engine performance
During the first three operating hours ≤ 75 %
– Avoid fully opening the throttle!

8.3 Starting power of lithium-ion batteries at low temperatures

Lithium-ion batteries are far lighter than lead batteries, have a low
self-discharge rate, and have more starting power at temperatures
over 15 °C (60 °F). At low temperatures, however, the starting
power of lithium-ion batteries drops to below that of lead batter-
ies.
Multiple starting attempts may be needed. Press the start button
for 5 seconds, and wait 30 seconds between attempts. The pauses
are necessary so that the heat created can distribute through the
lithium-ion battery and the lithium-ion battery is not damaged.
S03862-01 If the charged lithium-ion battery is unable to actuate the electric
starter when temperatures are below 15 °C (60 °F), the battery is
not faulty, but needs to be warmed up internally to increase its
starting power (current output).
The starting power increases as the battery warms up.

25
9 RIDING INSTRUCTIONS

9.1 Checks and maintenance measures when preparing for use

Info
Before every trip, check the condition of the vehicle and ensure that it is safe to operate.
The vehicle must be in perfect technical condition when it is being operated.

– Check the engine oil level. ( p. 108)

– Check the front brake fluid level. ( p. 73)
– Check the rear brake fluid level. ( p. 78)
– Check the front brake linings. ( p. 75)
– Check the rear brake linings. ( p. 80)
– Check that the brake system is functioning properly.
– Check the coolant level. ( p. 97)
– Check for chain dirt accumulation. ( p. 58)
H02217-01
– Check the chain, rear sprocket, and engine sprocket.
( p. 61)
– Check the chain tension. ( p. 59)
– Check the tire condition. ( p. 88)
– Check tire pressure. ( p. 89)
– Check the air filter.
– Check the settings of all controls and ensure that they can be
operated smoothly.
– Check all screws, nuts, and hose clips regularly for tightness.
– Check the fuel level.

9.2 Starting

Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.

Caution
Danger of accidents Electronic components and safety devices will be damaged if the 12-V battery is dis-
charged or missing.
– Never operate the vehicle with a discharged 12-V battery or without a 12-V battery.

Note
Engine damage Unfiltered intake air has a negative effect on the service life of the engine.
Dust and dirt will enter the engine without an air filter.
– Never start to use the vehicle without an air filter.

Note
Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.
– Always run the engine warm at a low speed.

26
 RIDING INSTRUCTIONS 9

– Remove plug-in stand 1.

– Shift the transmission into neutral.
Condition
Ambient temperature: < 20 °C (< 68 °F)
– Push the cold start button in all the way.

H03892-10

– Press start button .

Info
Press the start button for a maximum of 5 seconds.
Wait for 30 seconds before a further attempt at start-
ing.
At temperatures below 15 °C (60 °F), several attempts
at starting may be necessary to warm-up the lithium-ion
battery and thereby increase the starting power.
400733-01 During the starting process, the malfunction indicator
lamp lights up.

9.3 Activating launch control

Info
The launch control helps the rider to generate optimum motorcycle acceleration at the beginning of a race.
The maximum speed of the engine with the throttle valve fully opened (full throttle) is reduced. After the
start, it is gradually increased up to the maximum engine speed. The clutch must be operated exactly as it
would be without launch control activated.

Condition
The motorcycle is stationary.
The engine is running at idle speed.
The transmission is in neutral.
– Press and hold the MAP and TC buttons simultaneously.
The malfunction indicator lamp flashes orange rapidly.

Info
The launch control is deactivated automatically for a
few seconds after the vehicle has started.
The launch control is also deactivated in the following
cases (malfunction indicator lamp no longer flashes): if
the throttle valve is closed more than 1/3 of the way
H02884-01
after full throttle, and/or if there is no start within
3 minutes.
For safety reasons, the engine must be switched off for
at least 10 seconds before the launch control can be
activated again, regardless of whether the vehicle has
been started or not.

27
9 RIDING INSTRUCTIONS

9.4 Activating traction control

Info
The traction control reduces excessive slip on the rear wheel in favor of more control and propulsion, par-
ticularly in wet conditions.
When traction control is switched off, the rear wheel may spin more during high acceleration and on sur-
faces with low grip.
Traction control can be switched on or off during the ride.
The setting most recently selected is activated again when restarting.

– Press button TC to switch the traction control on or off.

Guideline
Engine speed ≤ 4,000 rpm
The TC LED lights up when the traction control is acti-
vated.

H02885-01

9.5 Starting off

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

Tip
If the engine dies while starting off, only pull the clutch lever and press the electric starter button. You
do not need to shift into neutral.

9.6 Shifting, riding

Warning
Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine
races.
– Do not change into a low gear at high engine speed.

Info
If unusual noises occur while riding, stop immediately (taking care not to endanger yourself or other road
users in the process), switch off the engine and contact an authorized KTM workshop.
First-gear is used for starting off and for steep inclines.

– Shift into a higher gear when conditions allow (incline, road

situation, etc.). To do so, release the throttle while simultane-
ously pulling the clutch lever, shift into the next gear, release
the clutch lever and open the throttle.
– If the cold start button was pushed while starting, open the
throttle briefly and release the throttle grip or turn the throttle
grip forward.
The cold start button goes to the basic position.

28
 RIDING INSTRUCTIONS 9

– After reaching maximum speed by fully opening the throttle

grip, turn the throttle back so it is ¾ open. This will barely
reduce the speed, but fuel consumption will be considerably
lower.
– Only open the throttle as much as the engine can handle –
abrupt throttle grip opening increases fuel consumption.
– To shift down, apply the brakes and close the throttle at the
same time.
– Pull the clutch lever and shift into a lower gear, release the
clutch lever slowly, and either open the throttle or shift again.
– Switch off the engine if you are likely to be running at idle
speed or stationary for a long time.
Guideline
≥ 1 min
– Avoid frequent or lengthy slipping of the clutch. This causes
the engine oil, engine and cooling system to heat up.
– Ride at a low engine speed instead of at a high engine speed
with a slipping clutch.
Condition
Quickshifter activated.

Note
Transmission damage Incorrect use of the quickshifter will
damage the transmission.
The quickshifter is only designed for shifting up under
load.
The quickshifter can only be used if the function is
S04069-01
enabled on the quickshifter switch.
– Use the quickshifter only to shift up under load.
– To shift in overrun condition or in load-free condition,
use the clutch lever for shifting.
– Pull the clutch lever to shift down.

– When the quickshifter is activated, you can shift up with-

out the clutch.

Info
Depress the shift lever to the stop quickly without
changing the throttle twist grip position.

9.7 Applying the brakes

Warning
Danger of accidents Moisture and dirt impair the brake system.
– Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs.

Warning
Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)

29
9 RIDING INSTRUCTIONS

Warning
Danger of accidents The brake system fails in the event of overheating.
If the foot brake lever is not released, the brake linings drag continuously.
– Take your foot off the foot brake lever when you are not braking.

Warning
Danger of accidents The rear wheel can lock due to the engine braking effect.
– Pull in the clutch, if you perform emergency or full braking, or if you brake on a slippery ground.

Warning
Danger of accidents Banked or laterally sloping ground reduces the maximum possible delay.
– If possible finish braking before going into a bend.

– Always finish braking before you go into a bend. Shift down to a lower gear appropriate to your speed.
– Use the braking effect of the engine on long downhill stretches. Shift back one or two gears, but do not over-
rev the engine when doing so. This means that significantly less braking is required and the brake system
does not overheat.

9.8 Stopping, parking

Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running.
– Protect the vehicle against access by unauthorized persons.

Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system
before the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.

Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
– Park the vehicle on a firm and level surface.
– Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.

Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
– Do not park the vehicle near to materials which are highly flammable or explosive.
– Allow the vehicle to cool down before covering it.

– Apply the brakes on the motorcycle.

– Shift the transmission into neutral.
– Press and hold the switch-off button while the engine is idling until the engine stops.
– Park the motorcycle on firm ground.

30
 RIDING INSTRUCTIONS 9

9.9 Transporting

Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.

Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
– Do not park the vehicle near to materials which are highly flammable or explosive.
– Allow the vehicle to cool down before covering it.

– Switch off the engine.

– Use tension belts or other suitable devices to secure the
motorcycle against falling over or rolling away.

401475-01

9.10 Refueling

Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.

Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.

Note
Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged.
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in
problems with the fuel system.
– Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to
help.)

31
9 RIDING INSTRUCTIONS

Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.

– Switch off the engine.

– Open the fuel tank filler cap. ( p. 17)
– Fill the fuel tank with fuel up to the lower edge 1 of the fuel
filler.
Total fuel tank 7l Super unleaded
capacity, approx. (1.8 US gal) (ROZ 95/RON
95/PON 91)
( p. 137)
S03979-10
– Close the fuel tank filler cap. ( p. 17)

32
 SERVICE SCHEDULE 10

10.1 Additional information

Any further work that results from the service work must be ordered separately and invoiced separately.
Different service intervals may apply in your country, depending on the local operating conditions.
Individual service intervals and scopes may change in the course of technical developments. The most up-to-date
service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise
you.

10.2 Service work

after every race
Every 30 operating hours
Every 20 operating hours
Every 15 operating hours
After 10 operating hours / Every 10 operating hours
Every 5 operating hours
After 1 operating hour
Read out the fault memory using the KTM diagnostics tool. ○ ● ● ● ● ● ●
Check that the electrical system is functioning properly. ○ ● ● ● ● ●
Change the engine oil and oil filter, clean the oil screen. ( p. 109) ○ ● ● ● ● ● ●
Check the brake discs. ( p. 73) ○ ● ● ● ● ● ●
Check the front brake linings. ( p. 75) ● ● ● ● ● ●
Check the rear brake linings. ( p. 80) ● ● ● ● ● ●
Check the fork bearing for play. ● ● ●
Check the heim joint for play. ● ● ● ● ● ●
Check the shock absorber linkage. ● ● ● ● ● ●
Check the tire condition. ( p. 88) ○ ● ● ● ● ● ●
Check tire pressure. ( p. 89) ○ ● ● ● ● ● ●
Check the brake lines for damage and tightness. ○ ● ● ● ● ● ●
Check the front brake fluid level. ( p. 73) ○ ● ●
Check the rear brake fluid level. ( p. 78) ○ ● ●
Check/correct the fluid level of hydraulic clutch. ( p. 69) ○ ● ●
Clean the dust boots of the fork legs. ● ●
Check the chain, rear sprocket, and engine sprocket. ( p. 61) ● ● ● ● ● ●
Check the chain tension. ( p. 59) ○ ● ● ● ● ● ●
Check the coolant level. ( p. 97) ○ ● ● ● ●
Clean the air filter box. ● ● ● ● ● ●
Change the air filter. ● ●
Check that the throttle cables are undamaged, routed without kinks, and set ○ ● ● ● ● ● ●
correctly.
Check the cables for damage and for routing without kinks. ● ● ● ● ● ●
Check the valve clearance. ○ ● ●
Check the clutch. ● ● ●
Change the cover seal and radial shaft seal rings of the water pump. ● ●
Change the glass fiber yarn filling of the main silencer. ( p. 64) ● ● ●
Service the fork. ● ● ●
Perform the shock absorber service. ○ ●
Check the fuel pressure. ● ● ● ● ● ●

33
10 SERVICE SCHEDULE

after every race

Every 30 operating hours
Every 20 operating hours
Every 15 operating hours
After 10 operating hours / Every 10 operating hours
Every 5 operating hours
After 1 operating hour
Change the fuel screen. ( p. 107) ○ ● ● ● ● ● ●
Check the idle speed. ○ ● ● ● ● ● ●
Change the front brake fluid. ● ● ● ●
Change the rear brake fluid. ● ● ● ●
Change the hydraulic clutch fluid. ( p. 70) ● ● ●
Check the steering head bearing play. ( p. 48) ○ ● ● ● ● ● ●
Check the fuel collecting container. ● ● ● ● ● ●
Check the coolant overflow reservoir. ● ● ● ● ● ●
Clean the oil separator. ●
Check the frame. ( p. 68) ● ● ● ● ● ●
Check the link fork. ( p. 68) ● ● ● ● ● ●
Check the wheel bearing for play. ● ● ● ● ● ●
Check the tightness of the safety-relevant screws and nuts which are easily ○ ● ● ● ● ● ●
accessible.
Grease all moving parts (e.g. side stand, hand lever, chain, etc.) and check for ○ ● ● ● ● ●
smooth operation.
Check all hoses (e.g. fuel, cooling, bleeder, drainage hoses, etc.) and sleeves ○ ● ● ● ● ● ●
for cracking, tightness, and correct routing.
Empty the drainage hoses. ○ ● ●
Change the fuel filter. ●
Perform engine service including removing and installing the engine. (Change ●
the spark plug and spark plug connector. Change the piston, check and mea-
sure the cylinder; check the cylinder head. Check the camshaft and cam lever.
Check the timing assembly. Change the intake flange. Change the valves, valve
springs, valve spring seats and valve spring retainers. Change the connecting
rod, conrod bearing and crank pin. Check the transmission and the shift mech-
anism. Check the oil pressure control valve. Change the suction pump. Check
the force pump and lubrication system. Change the timing chain. Change all
engine bearings. Change the freewheel.)
Read out the fault memory after the test ride using the KTM diagnostics tool. ○ ● ● ● ● ● ●
Final check: Check the vehicle for operating safety and take a test ride. ○ ● ● ● ● ● ●
Make a service entry in KTM Dealer.net. ○ ● ● ● ● ● ●
○ One-time interval
● Periodic interval

34
 TUNING THE CHASSIS 11

11.1 Adjusting the compression damping of the fork

Info
The hydraulic compression damping determines the fork suspension behavior.

– Turn adjusting screws 1 clockwise all the way.

Info
Adjusting screws 1are located at the bottom end of
the fork legs.
Do not loosen screw caps 2.

– Turn counterclockwise by the number of clicks corresponding

to the fork type.
S03980-10
Guideline
Compression damping
Standard 10 clicks

Info
Turn clockwise to increase damping; turn counterclock-
wise to reduce damping.

11.2 Adjusting the rebound damping of the fork

Info
The hydraulic rebound damping determines the fork suspension behavior.

– Turn adjusting screws 1 clockwise all the way.

Info
Adjusting screws 1 are located at the top end of the
fork legs.

– Turn counterclockwise by the number of clicks corresponding

to the fork type.
Guideline
S03981-10
Rebound damping
Standard 10 clicks

Info
Turn clockwise to increase damping; turn counterclock-
wise to reduce damping.

35
11 TUNING THE CHASSIS

11.3 Adjusting the spring preload of the fork

Preparatory work
– Raise the motorcycle with the rear lifting gear. ( p. 40)
– Lift the motorcycle with the front lifting gear. ( p. 40)
Main work
– Turn adjusting screws 1 counterclockwise all the way.
Info
Adjusting screws 1
are located at the top end of the
fork legs.
Make the same adjustment on both fork legs.

– Turn clockwise by the number of turns corresponding to the

S03981-11 fork type.
Guideline
Spring preload - Preload Adjuster
Standard 25 clicks

Info
Turning clockwise increases the preload; turning coun-
terclockwise reduces the spring preload.
Changing the spring preload has no influence on the
rebound damping although the adjusting screws turn
during the adjustment work. However, you should also
adjust the rebound damping when you alter the spring
preload.

Finishing work
– Take the motorcycle off the front lifting gear. ( p. 41)
– Remove the rear of the motorcycle from the lifting gear.
( p. 40)

11.4 Adjusting the spring preload of the shock absorber

Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)

Info
Note the current adjustment before changing the spring preload -–e.g. measure the spring length.

Preparatory work
– Remove the front spoiler. ( p. 54)
– Raise the motorcycle with a lift stand. ( p. 41)
– Remove the tail section. ( p. 55)
– Take off the front rider's seat along with the fuel tank cover.
( p. 53)
– Remove main silencer. ( p. 62)

36
 TUNING THE CHASSIS 11

– Remove the shock absorber. ( p. 49)

– After removing the shock absorber, clean it thoroughly.
Main work
– Loosen screw 1.
– Turn adjusting ring 2 until the spring is no longer under ten-
sion.
Hook wrench (90129051000)
– Measure the total spring length while the spring is not under
tension.
– Tension the spring by turning adjusting ring 2 to specified
dimension A .
Guideline
Spring preload 10 mm (0.39 in)

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

S03982-10
– Tighten screw 1.
Guideline
Screw, shock M5 5 Nm (3.7 lbf ft)
absorber adjusting
ring

Finishing work
– Install the shock absorber. ( p. 51)
– Install the main silencer. ( p. 63)
– Mount the front rider's seat along with the fuel tank cover.
( p. 54)
– Install the tail section. ( p. 55)
– Remove the motorcycle from the lift stand. ( p. 42)
– Fit the front spoiler. ( p. 54)

11.5 Compression damping of the shock absorber

The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.
High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle
speed.
The high-speed setting, for example, has an effect 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 slowly.
These two ranges can be adjusted separately, although the transition between high-speed and low-speed is grad-
ual. Thus, changes in the high-speed range affect the compression damping in the low-speed range and vice
versa.

37
11 TUNING THE CHASSIS

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

Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)

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

– Turn adjusting screw 1 all the way counterclockwise with a

socket wrench.

Info
Do not loosen fitting 2!
– Turn clockwise by the number of turns corresponding to the
shock absorber type.
Guideline
S03983-10
Highspeed compression damping
Standard 2 turns

Info
Turn clockwise to increase damping; turn counterclock-
wise to reduce damping.

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

Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)

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

– Turn adjusting screw 1 clockwise up to the last perceptible

click.

Info
Do not loosen fitting 2!
– Turn counterclockwise by the number of clicks corresponding
to the shock absorber type.

S03983-11

38
 TUNING THE CHASSIS 11

Guideline
Lowspeed compression damping
Standard 5 clicks

Info
Turn clockwise to increase damping; turn counterclock-
wise to reduce damping.

11.8 Adjusting the rebound damping of the shock absorber

Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)

– Turn adjusting screw 1 clockwise up to the last perceptible

click.
– Turn counterclockwise by the number of clicks corresponding
to the shock absorber type.
Guideline
Rebound damping
Standard 5 clicks

S03984-10
Info
Turn clockwise to increase damping; turn counterclock-
wise to reduce damping.

39
12 SERVICE WORK ON THE CHASSIS

12.1 Raising the motorcycle with rear lifting gear

Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.

– Mount the supports of the lifting gear.

Bushings kit (635299550001)
– Insert the adapter in the rear lifting gear.
Retaining adapter (61029955144)
Rear wheel work stand (69329955000)

Info
402346-01 The supports, the adapter and the lifting gear are
included in the scope of supply.

– Stand the motorcycle upright, align the lifting gear with the
link fork and the adapters, and raise the motorcycle.

12.2 Removing the rear of the motorcycle from the lifting gear

Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.

– Secure the motorcycle against falling over.

– Remove the rear lifting gear and lean the vehicle on plug-in
stand 1 .
– Remove the lifting gear supports.

H03892-10

12.3 Lifting the motorcycle with the front lifting gear

Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.

Preparatory work
– Raise the motorcycle with the rear lifting gear. ( p. 40)

40
 SERVICE WORK ON THE CHASSIS 12

Main work
– Move the handlebar to the straight-ahead position. Position the
lifting gear.
Front wheel lifting gear (A56029055000)

Info
Always raise the motorcycle at the rear first.

S03868-01
– Lift the motorcycle at the front.

12.4 Taking the motorcycle off the front lifting gear

Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.

Main work
– Secure the motorcycle against falling over.
– Remove the front lifting gear.

402777-01

Finishing work
– Remove the rear of the motorcycle from the lifting gear.
( p. 40)

12.5 Raising the motorcycle with a lift stand

Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
– Park the vehicle on a firm and level surface.
– Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.

Preparatory work
– Remove the front spoiler. ( p. 54)

41
12 SERVICE WORK ON THE CHASSIS

Main work
– Remove the plug-in stand and lift up the motorcycle by the
frame underneath the engine.
Lift stand (78929955100)
Neither wheel is in contact with the ground.
– Secure the motorcycle against falling over.

H03894-01

12.6 Removing the motorcycle from the lift stand

Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
– Park the vehicle on a firm and level surface.
– Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.

Main work
– Remove the motorcycle from the lift stand.
– Remove the lift stand.
– To park the motorcycle, insert plug-in stand 1 into the left
side of the wheel spindle.

Info
The plug-in stand is included.
Remove the plug-in stand before riding.
H03892-10

Finishing work
– Fit the front spoiler. ( p. 54)

12.7 Removing the fork legs

Preparatory work
– Remove the front spoiler. ( p. 54)
– Remove the trim along with the front. ( p. 56)
– Raise the motorcycle with the rear lifting gear. ( p. 40)
– Lift the motorcycle with the front lifting gear. ( p. 40)
– Remove the front fender. ( p. 52)
– Remove the front wheel. ( p. 85)

42
 SERVICE WORK ON THE CHASSIS 12

Main work
– Remove screws 1 and take off the brake caliper.
– Loosen screw 2 of the steering damper clamp.
– Loosen screws 3 of the handlebar stub on both sides.
– Hang the brake caliper to the side.

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

S03990-10

– Loosen screws 4. Remove the left fork leg.

– Repeat the operation on the right side.

S03991-10

12.8 Installing the fork legs

Main work
– Position the fork legs.

Info
Make sure the cables and wiring are positioned cor-
rectly.
The upper triple clamp must be flush with the upper
edge of the fork legs.
The support for the brake caliper is attached to the
right fork leg.

– Tighten screw 1.
Guideline
Screw, top triple M8 15 Nm (11.1 lbf ft)
clamp
– Tighten screws 2.
Guideline
Screw, bottom triple M8 12 Nm (8.9 lbf ft)
S03991-11
clamp
– Position the handlebar stub.

43
12 SERVICE WORK ON THE CHASSIS

– Tighten screws 3.
Guideline
Screw, handle- M6 Tightening sequence:
bar stub Tighten top first, then
bottom.
10 Nm (7.4 lbf ft)
Loctite®243™

– Position the brake caliper. Mount and tighten screws 4.

Guideline
Screw, front M10 45 Nm (33.2 lbf ft)
brake caliper Loctite®243™

S03992-10

– Align the steering damper horizontally and align the steering

damper clamp so that the damping rods are evenly extended.
– Tighten screw 5.
Guideline
Screw, steering M6 10 Nm (7.4 lbf ft)
damper clamp

S03993-10

Finishing work
– Install the front wheel. ( p. 85)
– Take the motorcycle off the front lifting gear. ( p. 41)
– Remove the rear of the motorcycle from the lifting gear.
( p. 40)
– Install the trim along with the front. ( p. 56)
– Fit the front spoiler. ( p. 54)

44
 SERVICE WORK ON THE CHASSIS 12

12.9 Removing the lower triple clamp

Condition
Front wheel removed.
The fork legs have been removed.
Preparatory work
– Remove the front spoiler. ( p. 54)
– Raise the motorcycle with a lift stand. ( p. 41)
– Remove the trim along with the front. ( p. 56)
Main work
– Remove screw 1.
– Remove screw 2.
– Take off the upper triple clamp.

Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
S03994-10

– Remove protective ring 3.

– Remove the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.

S03995-10

12.10 Installing the lower triple clamp

Main work
– Clean the bearing and sealing elements, check for damage,
and grease.
High viscosity grease ( p. 138)
– Insert the lower triple clamp with the steering stem. Mount
upper steering head bearing.
– Push on protective ring 1.
S03996-10

– Position the upper triple clamp.

– Mount screw 2, but do not tighten yet.

S03997-10

45
12 SERVICE WORK ON THE CHASSIS

– Push the fork legs into the triple clamp and handlebar stub
and position.

Info
The handlebar stub must be positioned underneath the
upper triple clamp.
Make sure the cables and wiring are positioned cor-
rectly.
The upper triple clamp must be flush with the upper
S03998-10 edge of the fork legs.

– Tighten screws 3 on both sides.

Guideline
Screw, bottom triple M8 12 Nm (8.9 lbf ft)
clamp

– Tighten screw 2.
Guideline
Screw, steering head, M20x1.5 12 Nm (8.9 lbf ft)
top

S03999-10

– Mount and tighten screw 4.

Guideline
Screw, top M8 20 Nm (14.8 lbf ft)
steering stem Loctite®243™

S03999-11

– Using a plastic hammer, tap lightly on the upper triple clamp

to avoid stresses.
– Tighten screws 5.
Guideline
Screw, top triple M8 15 Nm (11.1 lbf ft)
clamp

S03999-12

46
 SERVICE WORK ON THE CHASSIS 12

– Align the steering damper and tighten screw 6.

Guideline
Screw, steering M6 10 Nm (7.4 lbf ft)
damper clamp

S03993-11

– Position the handlebar stub and tighten screws 7.

Guideline
Screw, handle- M6 Tightening sequence:
bar stub Tighten top first, then
bottom.
10 Nm (7.4 lbf ft)
Loctite®243™

S03991-12

Finishing work
– Install the fork legs. ( p. 43)
– Install the trim along with the front. ( p. 56)
– Install the front wheel. ( p. 85)
– Take the motorcycle off the front lifting gear. ( p. 41)
– Remove the rear of the motorcycle from the lifting gear.
( p. 40)
– Check that the wiring harness, throttle cables, and brake and
clutch lines can move freely and are routed correctly.
– Check the steering head bearing play. ( p. 48)
– Remove the motorcycle from the lift stand. ( p. 42)
– Fit the front spoiler. ( p. 54)

47
12 SERVICE WORK ON THE CHASSIS

12.11 Checking the steering head bearing play

Warning
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam-
ages components.
– Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad
to help.)

Preparatory work
– Remove the front spoiler. ( p. 54)
– Raise the motorcycle with a lift stand. ( p. 41)
Main work
– Move the handlebar to the straight-ahead position. Move the
fork legs to and fro in the direction of travel.
Play should not be detectable on the steering head bearing.
» If there is detectable play:
– Adjust the steering head bearing play. ( p. 48)
– Move the handlebar to and fro over the entire steering range.

400738-11 It must be possible to move the handlebar easily over the

entire steering range. There should be no detectable detent
positions.
» If detent positions are detected:
– Adjust the steering head bearing play. ( p. 48)
– Check the steering head bearing and adjust if neces-
sary.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 42)
– Fit the front spoiler. ( p. 54)

12.12 Adjusting the steering head bearing play

Preparatory work
– Remove the front spoiler. ( p. 54)
– Raise the motorcycle with a lift stand. ( p. 41)
Main work
– Loosen screws 1.
– Remove screw 2.
– Loosen and retighten screw 3.
Guideline
Screw, steering head, M20x1.5 12 Nm (8.9 lbf ft)
top

S04000-10
– Using a plastic hammer, tap lightly on the upper triple clamp
to avoid stresses.
– Mount and tighten screw 2.
Guideline
Screw, top M8 20 Nm (14.8 lbf ft)
steering stem Loctite®243™

48
 SERVICE WORK ON THE CHASSIS 12

– Tighten screws 1.
Guideline
Screw, top triple M8 15 Nm (11.1 lbf ft)
clamp
– Check the steering head bearing play. ( p. 48)
Finishing work
– Remove the motorcycle from the lift stand. ( p. 42)
– Fit the front spoiler. ( p. 54)

12.13 Lubricating the steering head bearing

– Remove the lower triple clamp. ( p. 45)
– Install the lower triple clamp. ( p. 45)

Info
The steering head bearing is cleaned and lubricated in
the course of removal and installation of the lower triple
clamp.

H02387-01

12.14 Removing the shock absorber

Preparatory work
– Remove the front spoiler. ( p. 54)
– Raise the motorcycle with a lift stand. ( p. 41)
– Remove the tail section. ( p. 55)
– Take off the front rider's seat along with the fuel tank cover.
( p. 53)
– Remove main silencer. ( p. 62)
Main work
– Remove screw 1.
– Remove fitting 2.

Info
Raise the wheel slightly to be able to remove the screws
more easily.

S04009-10

– Remove screws 3.
– Remove the cover and pull foot brake cylinder with the spring
off the push rod.

S04010-10

49
12 SERVICE WORK ON THE CHASSIS

– Remove the connecting link of the chain.

– Take off the chain.

Info
Protect the components against damage by covering
them.

S04011-10

– Remove screw 4 of the shift linkage.

– Remove screws 5 and 6.
– Hang the footrest bracket to the side.

Info
Pay attention to the quickshifter cable.

S04012-10

– Remove screw 7 and 8.

– Hang the footrest bracket to the side.

S04013-10

– Remove nut 9 and the swingarm pivot.

– Push the link fork back and secure it against falling over.

S04014-10

– Hold the shock absorber and remove screw bk.

– Remove the shock absorber carefully at the bottom.

S04015-10

50
 SERVICE WORK ON THE CHASSIS 12

12.15 Installing the shock absorber

Main work
– Carefully position the shock absorber into the vehicle from the
bottom.
– Mount and tighten screw 1.
Guideline
Screw, top M10 60 Nm (44.3 lbf ft)
shock absorber Loctite®2701™

S04015-11

– Position the link fork and mount the swingarm pivot.

Info
Pay attention to flat area A.
– Mount and tighten nut 2.
Guideline
Nut, swingarm pivot M16x1.5 100 Nm
(73.8 lbf ft)
S04016-10

– Position the right footrest bracket.

– Mount and tighten screws 3.
Guideline
Screw, footrest M8 30 Nm (22.1 lbf ft)
bracket Loctite®2701™

S04013-11

– Position the left footrest bracket.

– Mount and tighten screws 4.
Guideline
Screw, footrest M8 30 Nm (22.1 lbf ft)
bracket Loctite®2701™

– Position the shift linkage.

– Mount and tighten screw 5.
S04012-11 Guideline
Screw, bell crank M6 6.5 Nm
shift lever (4.79 lbf ft)

– Mount the chain.

– Connect the chain with connecting link 6.
Guideline
The closed chain joint lock must face in the direction of
travel.

S04011-11

51
12 SERVICE WORK ON THE CHASSIS

– Position the foot brake cylinder along with the spring.

Push rod7 engages in the foot brake cylinder.
– Mount and tighten screws 8 as well as their covers.
Guideline
Screw, foot M6 9 Nm (6.6 lbf ft)
brake cylinder Loctite®243™

S04010-11

– Position the angle lever and linkage lever.

– Mount and tighten fitting 9.
Guideline
Nut, linkage lever on M14x1.5 60 Nm (44.3 lbf ft)
angle lever

Info

S04017-10
Pay attention to flat area B.
– Mount and tighten screw bk.
Guideline
Screw, bottom M10 60 Nm (44.3 lbf ft)
shock absorber Loctite®2701™

Info
Raise the wheel slightly to be able to mount the screw
more easily.

Finishing work
– Install the main silencer. ( p. 63)
– Mount the front rider's seat along with the fuel tank cover.
( p. 54)
– Install the tail section. ( p. 55)
– Remove the motorcycle from the lift stand. ( p. 42)
– Fit the front spoiler. ( p. 54)

12.16 Removing the front fender

– Remove quick releases 1. Pull off the fender sideways and
take it off toward the front.

S04001-10

52
 SERVICE WORK ON THE CHASSIS 12

12.17 Installing the front fender

– Position the front fender. Mount and tighten quick
releases 1 .
The fender engages in the holding lugs.

S04001-10

12.18 Taking off the front rider's seat along with the fuel tank cover
Preparatory work
– Remove the tail section. ( p. 55)
Main work
– Remove screws 1.
– Unlock quick releases 2.
– Lift off the seat along with the fuel tank cover.

S04002-10

53
12 SERVICE WORK ON THE CHASSIS

12.19 Mounting the front rider's seat along with the fuel tank cover
– Position the front rider's seat along with the fuel tank cover on
the motorcycle from above.
– Lock quick releases 1.
– Mount and tighten screws 2.
Guideline
Remaining screws, M5 5 Nm (3.7 lbf ft)
chassis
– Check that the front rider's seat is mounted correctly.

S04002-11

12.20 Removing the front spoiler

– Unlock quick releases 1 on both sides.
– Take off the front spoiler.

S04003-10

12.21 Fitting front spoiler

– Position the front spoiler.
– Lock quick releases 1 on both sides.

S04003-10

54
 SERVICE WORK ON THE CHASSIS 12

12.22 Removing the tail section

– Remove screws 1.
– Pull the tail section toward the rear to remove.

S04004-10

12.23 Installing the tail section

– Position the tail section.
– Mount and tighten screws 1.
Guideline
Remaining screws, M5 5 Nm (3.7 lbf ft)
chassis

S04004-10

55
12 SERVICE WORK ON THE CHASSIS

12.24 Removing the trim along with the front

Preparatory work
– Remove the front spoiler. ( p. 54)
Main work
– Unlock quick releases 1.
– Remove pin 2 on both sides.
– Pull trim laterally out of the retaining pins and pull toward the
front to remove.

S04005-10

12.25 Installing the trim along with the front

Main work
– Position the trim from the front and attach laterally into the
retaining pins.
– Mount pin 1 on both sides.
– Lock quick releases 2.
– Check that the trim is firmly seated.

S04006-10

Finishing work
– Fit the front spoiler. ( p. 54)

56
 SERVICE WORK ON THE CHASSIS 12

12.26 Removing the air filter

Note
Engine damage Unfiltered intake air has a negative effect on the service life of the engine.
Dust and dirt will enter the engine without an air filter.
– Never start to use the vehicle without an air filter.

Preparatory work
– Remove the tail section. ( p. 55)
– Take off the front rider's seat along with the fuel tank cover.
( p. 53)
Main work
– Detach retaining tab 1.
– Remove air filter with air filter support.
– Remove air filter from air filter support.

S04007-10

12.27 Cleaning the air filter and air filter box

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

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

Preparatory work
– Remove the tail section. ( p. 55)
– Take off the front rider's seat along with the fuel tank cover.
( p. 53)
– Remove the air filter. ( p. 57)
Main work
– Wash the air filter thoroughly in special cleaning liquid and
allow it to dry properly.
Air filter cleaner ( p. 138)

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

F01027-01
– Oil the dry air filter with a high-grade air filter oil.
Oil for foam air filter ( p. 138)
– Clean the air filter box.
– Clean the intake flange and check it for damage and tightness.

57
12 SERVICE WORK ON THE CHASSIS

Finishing work
– Install the air filter. ( p. 58)
– Mount the front rider's seat along with the fuel tank cover.
( p. 54)

12.28 Installing the air filter

Main work
– Mount the clean air filter on the air filter support.
– Grease the air filter in area A.
Long-life grease ( p. 138)

H02459-01

– Insert air filter and position retaining pin 1 in socket B.

The air filter is correctly positioned.
– Insert retaining tab 2.
Retaining pin 3 is secured by retaining tab 2.

Info
If the air filter is not mounted correctly, dust and dirt
may enter the engine and result in damage.
S04008-10

Finishing work
– Mount the front rider's seat along with the fuel tank cover.
( p. 54)

12.29 Checking for chain dirt accumulation

– Check the chain for coarse dirt accumulation.
» If the chain is very dirty:
– Clean the chain. ( p. 59)

400678-01

58
 SERVICE WORK ON THE CHASSIS 12

12.30 Cleaning the chain

Warning
Danger of accidents Lubricants on the tires reduces the road grip.
– Remove lubricants from the tires using a suitable cleaning agent.

Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

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

Preparatory work
– Raise the motorcycle with the rear lifting gear. ( p. 40)
Main work
– Clean the chain regularly.
– Rinse off loose dirt with a soft jet of water.
– Remove old grease remains with chain cleaner.
Chain cleaner ( p. 138)
– After drying, apply chain spray.
Street chain spray ( p. 139)
400725-01

Finishing work
– Remove the rear of the motorcycle from the lifting gear.
( p. 40)

12.31 Checking the chain tension

Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear
wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the
rear wheel locks or the engine will be damaged.
– Check the chain tension regularly.
– Set the chain tension in accordance with the specification.

Preparatory work
– Raise the motorcycle with the rear lifting gear. ( p. 40)

59
12 SERVICE WORK ON THE CHASSIS

Main work
– Shift the transmission into neutral.
– In the area behind the chain sliding guard, press the chain
upward toward the link fork and determine chain tension . A
Info
The top part of chainB must be taut.
Chains do not always wear evenly. Repeat this measure-
ment at different chain positions.

Chain tension 5 … 7 mm (0.2 … 0.28 in)

» If the chain tension does not meet the specification:
– Adjust the chain tension. ( p. 60)
– Remove the rear of the motorcycle from the lifting gear.
( p. 40)

S04018-10

12.32 Adjusting the chain tension

Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear
wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the
rear wheel locks or the engine will be damaged.
– Check the chain tension regularly.
– Set the chain tension in accordance with the specification.

Preparatory work
– Raise the motorcycle with the rear lifting gear. ( p. 40)
– Check the chain tension. ( p. 59)

60
 SERVICE WORK ON THE CHASSIS 12

Main work
– Loosen nut 1.
– Loosen nuts 2.
– Adjust the chain tension by turning adjusting screws 3 left
and right.
Guideline
Chain tension 5 … 7 mm (0.2 … 0.28 in)
Turn the adjusting screws 3 on the left and right so that
the markings on the left and right chain adjusters 4 are in
the same position relative to the reference marks A . The
rear wheel is then correctly aligned.

Info
The top part of the chain must be taut.
Chains do not always wear evenly, so you should check
the setting at different chain positions.

– Tighten nuts 2.
S04019-10
– Make sure that chain adjusters 4 are fitted correctly on
adjusting screws . 3
– Tighten nut 1 .
Guideline
Nut, rear wheel spin- M20x1.5 80 Nm (59 lbf ft)
dle

Finishing work
– Remove the rear of the motorcycle from the lifting gear.
( p. 40)

12.33 Checking the chain, rear sprocket, and engine sprocket

Preparatory work
– Raise the motorcycle with the rear lifting gear. ( p. 40)
Main work
– Shift the transmission into neutral.
– Check the rear sprocket and the engine sprocket for wear.
» If the rear sprocket and engine sprocket are worn:
– Change the drivetrain kit.

Info
The engine sprocket, the rear sprocket, and the
100132-10
chain should always be replaced together.

61
12 SERVICE WORK ON THE CHASSIS

– Pull on the lower chain section with specified weight A.

Guideline
Weight, chain wear measure- 15 kg (33 lb.)
ment
– Measure distance B of 20 chain rollers in the lower chain
section.

Info
Chains do not always wear evenly. Repeat this measure-
ment at different chain positions.

Maximum distance Bfrom 304 mm (11.97 in)

20 chain rollers at the
longest chain section
» If distance B is greater than the specified measurement:
– Change the drivetrain kit.

S04070-01
Info
When a new chain is mounted, the rear sprocket
and the engine sprocket should also be
changed.
New chains wear out faster on old, worn sprock-
ets.

– Push the chain up in the area behind the chain guide.

– Check the chain sliding guard for wear.
» If the chain sliding guard in area C has lost a large
amount of material due to wear.
– Change the chain sliding guard.
– Check that the chain sliding guard is firmly seated.
» If the chain sliding guard is loose:
– Tighten screws on the chain sliding guard.
S04020-10

Finishing work
– Remove the rear of the motorcycle from the lifting gear.
( p. 40)

12.34 Removing the main silencer

Preparatory work
– Remove the tail section. ( p. 55)
– Take off the front rider's seat along with the fuel tank cover.
( p. 53)

62
 SERVICE WORK ON THE CHASSIS 12

Main work
– Remove spring 1.
– Remove screws 2.
– Take off the main silencer.

S04021-10

12.35 Installing the main silencer

Main work
– Position the main silencer.
– Mount and tighten screws 1.
Guideline
Screw, main silencer M8 18 Nm (13.3 lbf ft)
– Mount spring 2.

S04022-10

Finishing work
– Mount the front rider's seat along with the fuel tank cover.
( p. 54)
– Install the tail section. ( p. 55)

63
12 SERVICE WORK ON THE CHASSIS

12.36 Changing the glass fiber yarn filling of the main silencer

Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.

Info
Over time, the fibers of the glass fiber yarn escape and the damper “burns” out.
Not only is the noise level higher, but the performance characteristics change.

Preparatory work
– Remove the tail section. ( p. 55)
– Take off the front rider's seat along with the fuel tank cover.
( p. 53)
– Remove main silencer. ( p. 62)
Main work
– Remove all the screws on the main silencer.
– Take off silencer cap 1 and O-ring 2.
– Pull glass fiber yarn filling 3 from the inner tube.
– Clean the parts that need to be reinstalled and check for dam-
age.
– 3 on the inner tube.
Mount new glass fiber yarn filling
– Insert O-ring 2 and silencer cap 1 into outer tube 4.
– Mount and tighten all of the screws.
Guideline
Screws on main M5 7 Nm (5.2 lbf ft)
silencer

S03540-10

Finishing work
– Install the main silencer. ( p. 63)
– Mount the front rider's seat along with the fuel tank cover.
( p. 54)
– Install the tail section. ( p. 55)

64
 SERVICE WORK ON THE CHASSIS 12

12.37 Removing the fuel tank

Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.

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

Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.

Preparatory work
– Remove the tail section. ( p. 55)
– Take off the front rider's seat along with the fuel tank cover.
( p. 53)
– Remove the front spoiler. ( p. 54)
– Remove the trim along with the front. ( p. 56)
Main work
– Remove fuel collecting container 1 and coolant collecting
container .2

S04023-10

– Unplug connector 3 of the fuel pump.

S04024-10

65
12 SERVICE WORK ON THE CHASSIS

– Clean plug-in connection 4 of the fuel line thoroughly with

compressed air.

Info
Under no circumstances should dirt enter into the fuel
line. Dirt in the fuel line clogs the injection valve!

– Disconnect the quick release coupling.

– Mount wash cap set 5.
S04025-10
Wash cap set (81212016100)

– Remove screw 6.
– Remove the fuel tank from above.

S04026-10

12.38 Installing the fuel tank

Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.

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

Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.

Main work
– Check the throttle cable routing. ( p. 68)

66
 SERVICE WORK ON THE CHASSIS 12

– Position the fuel tank.

– Mount and tighten screw 1.
Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis

S04026-11

– Plug in connector 2 for the fuel pump.

S04024-11

– Remove the wash cap set. Clean the quick release coupling
thoroughly with compressed air.

Info
Under no circumstances should dirt enter into the fuel
line. Dirt in the fuel line clogs the injection valve!

– Lubricate the O-ring and connect plug-in connection 3 for

the fuel line.
S04027-10

– Mount fuel collecting container 4 and coolant collecting con-

tainer 5 .

S04023-11

Finishing work
– Install the trim along with the front. ( p. 56)
– Fit the front spoiler. ( p. 54)
– Mount the front rider's seat along with the fuel tank cover.
( p. 54)
– Install the tail section. ( p. 55)

67
12 SERVICE WORK ON THE CHASSIS

12.39 Checking the frame

– Check the frame for cracks and deformation.
» If the frame exhibits cracks or deformation due to a
mechanical impact:
– Change the frame.

Info
Always replace a frame that has been dam-
aged due to a mechanical impact. Repair of the
frame is not authorized by KTM.
S02306-01

12.40 Checking the link fork

– Check the link fork for damage, cracking, and deformation.
» If the link fork shows signs of damage, cracking, or defor-
mation:
– Change the link fork.

Info
Always replace a damaged link fork. Repairing
the link fork is not authorized by KTM.
S02305-01

12.41 Checking the throttle cable routing

Preparatory work
– Remove the tail section. ( p. 55)
– Take off the front rider's seat along with the fuel tank cover.
( p. 53)
– Remove the front spoiler. ( p. 54)
– Remove the trim along with the front. ( p. 56)
– Remove the fuel tank. ( p. 65)
Main work
– Check the throttle cable routing.
Both throttle cables must be routed, side by side, on the
back of the handlebars and above the fuel tank bracket, to
the throttle valve body. Both throttle cables must be secured
behind the rubber strap of the fuel tank support.
» If the throttle cable routing is not as specified:
– Correct the throttle cable routing.
S04028-10

Finishing work
– Install the fuel tank. ( p. 66)
– Install the trim along with the front. ( p. 56)
– Fit the front spoiler. ( p. 54)
– Mount the front rider's seat along with the fuel tank cover.
( p. 54)
– Install the tail section. ( p. 55)

68
 SERVICE WORK ON THE CHASSIS 12

12.42 Checking the rubber grips

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

Info
The rubber grips are vulcanized onto a sleeve on the
left and onto the handle tube of the throttle grip on the
right. The left sleeve is clamped onto the handlebar.
The rubber grip can only be replaced with the sleeve or
the throttle tube.
S03866-01
» If a rubber grip is damaged or worn:
– Change the rubber grip.
– Check that screw 1 is firmly seated.
Guideline
Screw, fixed M4 5 Nm (3.7 lbf ft)
grip Loctite®243™

Diamond A must be positioned visibly as shown in the fig-

ure.

S04029-10

12.43 Checking/correcting the fluid level of hydraulic clutch

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

Info
The fluid level rises with increasing wear of the clutch facing discs.
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.

Preparatory work
– Remove the front spoiler. ( p. 54)
– Remove the trim along with the front. ( p. 56)

69
12 SERVICE WORK ON THE CHASSIS

Main work
– Remove screw 1.
– Move the hydraulic clutch fluid reservoir into a horizontal posi-
tion.
– Take off screw cap 2 with membrane 3 and the shim.
– Check the fluid level.
Guideline
The fluid level must be between the MIN and MAX markings.
S04030-10
» If the fluid level does not meet specifications:
– Correct the fluid level of the hydraulic clutch.
Brake fluid DOT 4 / DOT 5.1 ( p. 136)
– Mount and tighten screw cap 2 with membrane 3 and the
shim.

Info
Use water to immediately clean up any brake fluid that
has overflowed or spilled.

– Position the compensating tank, and mount and tighten

screw 1
.
Finishing work
– Install the trim along with the front. ( p. 56)
– Fit the front spoiler. ( p. 54)

12.44 Changing the hydraulic clutch fluid

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

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

Info
The fluid level rises with increasing wear of the clutch facing discs.
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.

70
 SERVICE WORK ON THE CHASSIS 12

Preparatory work
– Remove the front spoiler. ( p. 54)
– Remove the trim along with the front. ( p. 56)
Main work
– Remove screw 1.
– Remove screw cap 2 with membrane 3.
– Move the hydraulic clutch fluid reservoir into a horizontal posi-
tion.
– Fill bleeding syringe 4 with the appropriate hydraulic fluid.
Syringe (50329050000)
Brake fluid DOT 4 / DOT 5.1 ( p. 136)
– On the clutch slave cylinder, remove the protection cap and
mount bleeding syringe 4with an appropriate hose piece on
bleeder screw 5 .
– Only loosen bleeder screw 5on the clutch slave cylinder to
the point where filling is possible.

Info
Use water to immediately clean up any brake fluid that
has overflowed or spilled.
S04031-10 Avoid contact between brake fluid and painted parts.
Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.

– Inject the liquid into the system until it escapes from open-
ing 6 of the master cylinder without bubbles.
– Occasionally extract the fluid from the master cylinder reser-
voir to prevent overflowing.
– Tighten bleeder screw 5
and remove bleeding syringe 4
along with the hose. Mount the protection cap.
– Correct the fluid level of the hydraulic clutch.
Guideline
S04032-10 The fluid level must be between the MIN and MAX markings.
– Position screw cap 2 with membrane 3. Mount and tighten
screw 1 .
Finishing work
– Install the trim along with the front. ( p. 56)
– Fit the front spoiler. ( p. 54)

71
12 SERVICE WORK ON THE CHASSIS

12.45 Adjusting the basic position of the clutch lever

– Adjust the basic position of the clutch lever to your hand size
by turning adjusting wheel 1 .

Info
Do not make any adjustments while riding.

S03967-11

72
 BRAKE SYSTEM 13

13.1 Checking the brake discs

Warning
Danger of accidents Worn-out brake discs reduce the braking effect.
– Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will
be glad to help.)

– Check the front and rear brake disc thickness at multiple

points for the dimension . A
Info
Wear will reduce the thickness of the brake disc at con-
tact surface1 of the brake linings.

Brake discs - wear limit

front 4.0 mm (0.157 in)
400480-10
rear 3.6 mm (0.142 in)
» If the brake disc thickness is less than the specified value.
– Change the front brake disc.
– Change the rear brake disc.
– Check the front and rear brake discs for damage, cracking, and
deformation.
» If the brake disc exhibits damage, cracking, or deforma-
tion:
– Change the front brake disc.
– Change the rear brake disc.

13.2 Checking the front brake fluid level

Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are
worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)

Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)

73
13 BRAKE SYSTEM

– Move the brake fluid reservoir mounted on the handlebar to a

horizontal position.
– Check the brake fluid level in brake fluid reservoir 1.
» If the brake fluid level is below the MIN marking:
– Add front brake fluid. ( p. 74)

S04033-10

13.3 Adding front brake fluid

Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are
worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)

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

Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.

Preparatory work
– Check the front brake linings. ( p. 75)

74
 BRAKE SYSTEM 13

Main work
– Take off screw cap 1 with membrane 2 and the shim.
– Add brake fluid up to the MAX‑ marking.
Brake fluid DOT 4 / DOT 5.1 ( p. 136)
– Mount screw cap 1 with membrane 2 and the shim.
Info
Use water to immediately clean up any brake fluid that
S04034-10
has overflowed or spilled.

13.4 Checking the front brake linings

Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be
glad to help.)

Warning
Danger of accidents Damaged brake discs reduce the braking effect.
If the brake linings are not changed in time, the brake lining carriers grind against the brake disc. As a
consequence, the braking effect is greatly reduced and the brake discs are destroyed.
– Check the brake linings regularly.

– Check the brake linings for minimum thickness A.

Minimum thickness A ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

– Change the brake linings of the front brake.
( p. 75)
– Check the brake linings for damage and cracking.
» If there is wear or tearing:
S04035-10 – Change the brake linings of the front brake.
( p. 75)

13.5 Changing the brake linings of the front brake

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

75
13 BRAKE SYSTEM

Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)

Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.

Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient
of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologa-
tion is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the
warranty shall be void.
– Only use brake linings approved and recommended by KTM.

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.

– Move the brake fluid reservoir mounted on the handlebar to a

horizontal position.
– Take off screw cap 1 with the membrane and the shim.

S04034-11

– Remove clips 2.

S04042-10

76
 BRAKE SYSTEM 13

– Remove pin 3.
– Take off spring 4.

S04042-11

– Press the brake piston with the help of the worn brake linings
back into the basic position and ensure that brake fluid does
not flow out of the brake fluid reservoir, extracting some if nec-
essary.
– Remove brake linings 5.
– Clean brake caliper.
– Position new brake linings 5.
S04043-10 Info
Always change the brake linings in pairs.

– Position spring 4.
The arrow on the spring points in the direction of rotation.
– Mount pin 3.
Info
Ensure that the spring is correctly seated.

S04042-11

– Mount clips 2.
– Operate the hand brake lever until a firm pressure point is
present.

S04042-10

– Add brake fluid up to the MAX marking.

Brake fluid DOT 4 / DOT 5.1 ( p. 136)
– Mount screw cap 1 with the membrane and the shim.
Info
Use water to immediately clean up any brake fluid that
has overflowed or spilled.

S04034-11

77
13 BRAKE SYSTEM

13.6 Adjusting the basic position of the hand brake lever

– Adjust the basic position of the hand brake lever to your hand
size by turning adjusting wheel 1 .

Info
Do not make any adjustments while riding.

S03968-12

13.7 Checking the rear brake fluid level

Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are
worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)

Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)

Preparatory work
– Remove the tail section. ( p. 55)
– Take off the front rider's seat along with the fuel tank cover.
( p. 53)
Main work
– Position the vehicle vertically.
– Check the brake fluid level in brake fluid reservoir 1.
» If the brake fluid level has dropped below the MIN marking:
– Add rear brake fluid. ( p. 78)

S04036-10

13.8 Adding rear brake fluid

Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are
worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)

78
 BRAKE SYSTEM 13

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

Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.

Preparatory work
– Check the rear brake linings. ( p. 80)
Main work
– Position the vehicle vertically.
– Remove screw cap 1 with membrane 2 and the shim.
– Add brake fluid up to the MAX marking.
Brake fluid DOT 4 / DOT 5.1 ( p. 136)
– Mount screw cap 1 with membrane 2 and the shim.
S04037-10
Info
Use water to immediately clean up any brake fluid that
has overflowed or spilled.

79
13 BRAKE SYSTEM

13.9 Checking the rear brake linings

Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be
glad to help.)

Warning
Danger of accidents Damaged brake discs reduce the braking effect.
If the brake linings are not changed in time, the brake lining carriers grind against the brake disc. As a
consequence, the braking effect is greatly reduced and the brake discs are destroyed.
– Check the brake linings regularly.

– Check the brake linings for minimum thickness A.

Minimum thickness A ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

– Change the rear brake linings. ( p. 80)
– Check the brake linings for damage and cracking.
» If there is wear or tearing:
– Change the rear brake linings. ( p. 80)
S04038-10

13.10 Changing the rear brake linings

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

Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)

Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.

80
 BRAKE SYSTEM 13

Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient
of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologa-
tion is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the
warranty shall be void.
– Only use brake linings approved and recommended by KTM.

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.

– Position the vehicle vertically.

– Take off screw cap 1 with the washer and membrane.
– Manually press the brake caliper toward the brake disc to push
back the brake piston. Ensure that brake fluid does not flow
out of the brake fluid reservoir, if necessary extract excess.

S04037-11

– Remove latch 2.
– Remove pin 3.

S04044-10

– Remove brake linings 4.

– Clean brake caliper.
– Position new brake linings 4.
Info
Always change the brake linings in pairs.
Check that the brake linings are seated properly.

– Mount pin 3.
S04045-10

81
13 BRAKE SYSTEM

– Mount latch 2.

S04044-10

– Operate the foot brake lever repeatedly until the brake lin-
ings are in contact with the brake disc and there is a pressure
point.
– Adjust the brake fluid level to the MAX marking.
Brake fluid DOT 4 / DOT 5.1 ( p. 136)
– Mount and tighten screw cover 1 with the shim and the
membrane.

S04037-11
Info
Use water to immediately clean up any brake fluid that
has overflowed or spilled.

13.11 Adjusting the basic position of the foot brake lever

Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear
brake.
– Set the free travel on the foot brake lever in accordance with the specification.

Main work
– To adjust the basic position of the foot brake lever to individ-
ual requirements, loosen screw 1 and eccentric 2
accord-
ingly.

Info
The range of adjustment is limited.

– Tighten screw 1.
S04039-10
Guideline
Remaining nuts, M6 10 Nm (7.4 lbf ft)
chassis

Finishing work
– Adjust the free travel of the foot brake lever. ( p. 83)

82
 BRAKE SYSTEM 13

13.12 Checking the free travel of the foot brake lever

Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear
brake.
– Set the free travel on the foot brake lever in accordance with the specification.

– Move the foot brake lever back and forth between the end stop
and the contact to the foot brake cylinder piston and check
free travel A
.
Guideline
Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in)
» If the free travel does not match the specification:
– Adjust the free travel of the foot brake lever.
( p. 83)
S04040-10

13.13 Adjusting the free travel of the foot brake lever

Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear
brake.
– Set the free travel on the foot brake lever in accordance with the specification.

– Release nut 1 and use screw 2 to adjust the specified free

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

Info
The range of adjustment is limited.

– Hold screw 2 and tighten nut 1.

Guideline
Remaining nuts, M6 10 Nm (7.4 lbf ft)
chassis

S03975-11

83
13 BRAKE SYSTEM

13.14 Adjusting the foot brake lever resistance

– Loosen lock nut 1.
– Adjust the desired foot brake lever resistance using nut 2.
Info
The spring must at least be pretensioned so that the
foot brake lever can be depressed fully.
The range of adjustment is limited.

– Hold nut 2 and tighten lock nut 1.

S04041-10

84
 WHEELS, TIRES 14

14.1 Removing the front wheel

Preparatory work
– Raise the motorcycle with the rear lifting gear. ( p. 40)
– Lift the motorcycle with the front lifting gear. ( p. 40)
– Remove the front fender. ( p. 52)
Main work
– Loosen screws 1.
– Loosen wheel spindle 2.
Warning
Danger of accidents Damaged brake discs reduce the
braking effect.
– Always lay the wheel down in such a way that the
S04046-10 brake disc is not damaged.

– Hold front wheel and remove wheel spindle. Take the front
wheel out of the fork.

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

14.2 Installing the front wheel

Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.

Main work
– Remove spacers 1.
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Change front wheel bearing.
– Clean and grease the contact surfaces A of the spacers.
Long-life grease ( p. 138)
– Insert the spacers.
– Position the front wheel.
The brake linings are correctly positioned.
– Mount and tighten wheel spindle 3.
Guideline
Screw, front wheel M50 50 Nm (36.9 lbf ft)
spindle
– Operate the hand brake lever repeatedly until the brake lin-
ings are in contact with the brake disc and there is a pressure
S04047-10 point.
– Take the motorcycle off the front lifting gear. ( p. 41)

85
14 WHEELS, TIRES

– Operate the front brake and compress the fork a few times
firmly.
The fork legs straighten.
– Tighten screws 4.
Guideline
Screw, fork stub M8 15 Nm (11.1 lbf ft)

Finishing work
– Take the motorcycle off the front lifting gear. ( p. 41)
– Remove the rear of the motorcycle from the lifting gear.
( p. 40)

14.3 Removing the rear wheel

Preparatory work
– Raise the motorcycle with the rear lifting gear. ( p. 40)
Main work
– Remove nut 1 with the washer. Take off chain adjuster 2.
– Hold the rear wheel and pull out wheel spindle 3 with the
washer and chain adjuster 2.
– Push the rear wheel forward as far as possible and take the
chain off the rear sprocket.

Warning
Danger of accidents Damaged brake discs reduce the
braking effect.
– Always lay the wheel down in such a way that the
brake disc is not damaged.

– Pull the rear wheel back and take it out of the link fork.

Info
Do not operate the foot brake lever when the rear wheel
is removed.
S04019-11

14.4 Installing the rear wheel

Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.

Warning
Danger of accidents There is no braking effect to start with at the rear brake after installing the rear
wheel.
– Actuate the foot brake several times before going on a ride until you can feel a firm pressure point.

Main work
– Check the rear hub damping rubber pieces.

86
 WHEELS, TIRES 14

– Remove spacers 1.
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Change the rear wheel bearing.
– Clean and grease the contact surfaces A of the spacers.
Long-life grease ( p. 138)
– Insert the spacers.
S04048-10

– Clean the thread of the wheel spindle and nut.

– Clean and grease wheel spindle.
Long-life grease ( p. 138)
– Clean the contact areas on the brake caliper bracket and link
fork.
– Position the rear wheel.
The brake linings are correctly positioned.
– Push the rear wheel forward as far as possible and lay the
chain on the rear sprocket.
– Pull the rear wheel back and mount wheel spindle 2 with the
washers and chain adjusters .3
Info
Mount left and right chain adjusters 3 in the same
position.

– Mount nut 4, but do not tighten yet.

S04019-12 – Ensure that the chain adjusters lie flat on the adjusting screws
and tighten the nut . 4
Guideline
In order for the rear wheel to be correctly aligned, the mark-
ings on the left and right chain adjusters must be in the
same position relative to reference markings B .

Nut, rear wheel spin- M20x1.5 80 Nm (59 lbf ft)

dle

Finishing work
– Check the chain tension. ( p. 59)
– Remove the rear of the motorcycle from the lifting gear.
( p. 40)

87
14 WHEELS, TIRES

14.5 Checking the tire condition

Warning
Danger of accidents If a tire bursts while riding, the vehicle becomes uncontrollable.
– Ensure that damaged or worn tires are replaced immediately. (Your authorized KTM workshop will be
glad to help.)

Warning
Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling charac-
teristic.
Different tire tread patterns can make the vehicle significantly more difficult to control.
– Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.

Warning
Danger of accidents Non-approved or non-recommended tires and wheels impact the handling character-
istic.
– Only use tires/wheels approved by KTM with the corresponding speed index.

Info
The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the
motorcycle.
Worn tires have a negative effect on handling characteristics, especially on wet surfaces.

– Check the front and rear tires for cuts, embedded objects, and
other damage.
» If the tires have cuts, run-in objects, or other damage:
– Change the tires.
– Check tire wear.
» If the tire is worn:
– Change the tires.

400602-10

– Check the tire age.

Info
The tire date of manufacture is usually contained in the
tire label and is indicated by the last four digits of the
DOT number. The first two digits indicate the week of
manufacture and the last two digits the year of manu-
facture.
KTM recommends that the tires be changed after 5
H01144-10 years at the latest, regardless of the actual state of
wear.

» If the tires are more than 5 years old:

– Change the tires.

88
 WHEELS, TIRES 14

14.6 Checking tire pressure

Info
Low tire pressure leads to abnormal wear and overheating of the tire.
Correct tire pressure ensures optimal riding comfort and maximum tire service life.

– Remove the protection cap.

– Check the tire pressure when the tires are cold.
Tire pressure (cold)
front 1.9 bar (28 psi)
rear 1.9 bar (28 psi)

Tire pressure (80° warm)

front 2.3 bar (33 psi)
400695-01
rear 2.1 bar (30 psi)
» If the tire pressure does not meet specifications:
– Correct the tire pressure.
– Mount the protection cap.

89
15 ELECTRICAL SYSTEM

15.1 Removing the 12-V battery

Caution
Danger of burns The voltage regulator gets very hot when the vehicle is driven.
– Allow the voltage regulator to cool down before performing any work.

Note
Environmental hazard 12 V batteries contain environmentally hazardous materials.
– Do not dispose of 12 V batteries as household waste.
– Dispose of 12 V batteries at a collection point for used batteries.

Preparatory work
– Press and hold the switch-off button while the engine is
idling until the engine stops.
– Remove the tail section. ( p. 55)
– Take off the front rider's seat along with the fuel tank cover.
( p. 53)
Main work
– Hang the voltage regulator to the side.
– Disconnect negative cable 1 from the 12-V battery.
– Pull back positive terminal cover 2 and disconnect the posi-
tive cable from the 12-V battery.
– Remove screw 3.
– Pull holding bracket 4 forward and remove the 12-V battery
upwards.

S04049-10

90
 ELECTRICAL SYSTEM 15

15.2 Installing the 12-V battery

Main work
– Insert the 12-V battery into the battery compartment with the
terminals facing forward and secure with holding bracket . 1
12-V battery (HJTZ5S-FP-C) ( p. 124)
– Mount and tighten screw 2.
Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis
– Connect positive cable 3 to the 12-V battery.
Guideline
Screw, battery termi- M5 2.5 Nm
nal (1.84 lbf ft)
– Connect negative cable 4 to the 12-V battery.
Guideline
Screw, battery termi- M5 2.5 Nm
nal (1.84 lbf ft)
S04050-10
– Slide the positive terminal cover over the positive terminal.
– Position the voltage regulator.
Finishing work
– Mount the front rider's seat along with the fuel tank cover.
( p. 54)

15.3 Charging the 12-V battery

Warning
Risk of injury 12 V batteries contain harmful substances.
– Keep 12 V batteries out of the reach of children.
– Keep sparks and open flames away from 12 V batteries.
– Only charge 12 V batteries in well-ventilated rooms.
– Maintain a minimum clearance from inflammable materials when charging 12 V batteries.
Minimum clearance 1 m (3 ft)
– Do not charge deeply discharged 12 V batteries if the charge is already below the minimum voltage.
Minimum voltage before the start of the charge 9V
– Dispose of 12 V batteries with less than the minimum voltage correctly.

Note
Environmental hazard 12 V batteries contain environmentally hazardous materials.
– Do not dispose of 12 V batteries as household waste.
– Dispose of 12 V batteries at a collection point for used batteries.

91
15 ELECTRICAL SYSTEM

Info
Even when there is no load on the 12-V battery, it discharges steadily each day.
The charging level and the method of charging are very important for the service life of the 12-V battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, or charging time is exceeded, the 12 V battery will be destroyed.
If the 12-V battery is depleted by repeated starting, the 12-V battery must be charged immediately.
If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged
and suffer a loss of capacity, destroying the battery.
The 12-V battery is maintenance-free.

Preparatory work
– Press and hold the switch-off button while the engine is
idling until the engine stops.
– Remove the tail section. ( p. 55)
– Take off the front rider's seat along with the fuel tank cover.
( p. 53)
– Remove the 12-V battery. ( p. 90)
Main work
– Check the battery voltage.
» Battery voltage: < 9 V
– Do not charge the 12-V battery.
– Replace the 12-V battery and dispose of the old 12-V
battery properly.
» If the specifications have been met:
Battery voltage: ≥ 9 V
F01568-10 – Connect a battery charger to the 12-V battery. Switch
on the battery charger.
Guideline
The charging current, charging voltage, and charging
time must not be exceeded.
Maximum charging volt- 14.4 V
age
Maximum charging cur- 3.0 A
rent
Maximum charging time 24 h
Recharge the 12-V bat- 6 months
tery regularly when the
motorcycle is not being
used

(EU) battery charger (79629974000)

Alternative 1
(US) battery charger (79629974500)
These battery chargers test whether the 12-V battery
retains its voltage. It is also impossible to overcharge
the 12-V battery with these battery chargers. The
charging time may be longer at low temperatures.

92
 ELECTRICAL SYSTEM 15

These battery chargers are only suitable for lithium iron

phosphate batteries. Read the accompanying KTM Pow-
erParts instructions.

Info
Never remove cover 1.
– Switch off the battery charger after charging and disconnect
from the 12-V battery.
Finishing work
– Install the 12-V battery. ( p. 91)
– Mount the front rider's seat along with the fuel tank cover.
( p. 54)

15.4 Changing main fuse

Warning
Fire hazard Incorrect fuses overload the electrical system.
– Only use fuses with the required ampere value.
– Do not bypass or repair fuses.

Caution
Danger of burns The voltage regulator gets very hot when the vehicle is driven.
– Allow the voltage regulator to cool down before performing any work.

Info
The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under
the seat.

Preparatory work
– Press and hold the switch-off button while the engine is
idling until the engine stops.
– Remove the tail section. ( p. 55)
– Take off the front rider's seat along with the fuel tank cover.
( p. 53)
Main work
– Pull starter relay 1 from the holder.

S04051-10

93
15 ELECTRICAL SYSTEM

– 2.
Take off protection caps
– Remove faulty main fuse 3.

Info
A faulty fuse has a burned-out fuse wire A .
A spare fuse 4 is located in the starter relay.

– Insert a new main fuse.

Fuse (75011088010) ( p. 124)
– Check that the electrical system is functioning properly.

Tip
Insert a spare fuse so that it is available if needed.

– Mount the protection caps.

– Mount the starter relay onto the holder and route the cable.

S04052-10

Finishing work
– Mount the front rider's seat along with the fuel tank cover.
( p. 54)
– Install the tail section. ( p. 55)

15.5 Changing the fuse of individual power consumers

Info
The fuse for each power consumer is located on the right above the main silencer.

Preparatory work
– Switch off the ignition by turning the ignition key to the posi-
tion .
– Remove the tail section. ( p. 55)
– Take off the front rider's seat along with the fuel tank cover.
( p. 53)
Main work
– Open the fuse cover.
– Remove the faulty fuse.
Guideline
Fuse 1 - 7.5 A - combination instrument, tail light, quick-
shifter

Info
S04053-10 A faulty fuse has a burned-out fuse wire A.

94
 ELECTRICAL SYSTEM 15

Warning
Fire hazard Incorrect fuses overload the electrical sys-
tem.
– Only use fuses with the required ampere value.
– Do not bypass or repair fuses.

– Insert the spare fuse with the correct rating.

Fuse (067038485) ( p. 124)
– Check that the power consumers are functioning properly.
– Close the fuse cover.
Finishing work
– Mount the front rider's seat along with the fuel tank cover.
( p. 54)
– Install the tail section. ( p. 55)

15.6 Diagnostics connector

Diagnostics connector 1 is located under the front rider's seat.

S04092-01

95
16 COOLING SYSTEM

16.1 Cooling system

Water pump 1in the engine ensures forced circulation of the
coolant.
The pressure resulting from the warming of the cooling system is
regulated by a valve in radiator cap 2
. This ensures that operat-
ing the vehicle at the specified coolant temperature will not result
in a risk of malfunctions.
120 °C (248 °F)
Cooling is effected by the air stream.
S04054-10 The lower the speed, the less the cooling effect. Dirty cooling fins
also reduce the cooling effect.

16.2 Checking the antifreeze and coolant level

Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the
cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses
or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.

Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.

Condition
The engine is cold.
– Stand the motorcycle upright on a horizontal surface.
– Take off the radiator cap.
– Check the antifreeze in the coolant.
−25 … −45 °C (−13 … −49 °F)
» If the antifreeze in the coolant does not match the speci-
fied value:
– Correct the antifreeze in the coolant.
400243-10 – Check the coolant level in the radiator.

Coolant level A above the 10 mm (0.39 in)

radiator fins
» If the coolant level does not match the specified value:
– Correct the coolant level.
Coolant ( p. 136)
– Mount the radiator cap.

96
 COOLING SYSTEM 16

16.3 Checking the coolant level

Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the
cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses
or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.

Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.

Condition
The engine is cold.
– Stand the motorcycle upright on a horizontal surface.
– Take off the radiator cap.
– Check the coolant level in the radiator.

Coolant level A above the 10 mm (0.39 in)

radiator fins
» If the coolant level does not match the specified value:
– Correct the coolant level.
400243-10 Coolant ( p. 136)
– Mount the radiator cap.

16.4 Draining the coolant

Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the
cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses
or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.

97
16 COOLING SYSTEM

Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.

Condition
The engine is cold.
Preparatory work
– Remove the front spoiler. ( p. 54)
Main work
– Position the motorcycle upright.
– Place an appropriate container under the water pump cover.
– Remove screw 1. Take off radiator cap 2.
– Completely drain the coolant.
– Mount and tighten screw 1 with a new seal ring.
Guideline
Screw, water pump M6 10 Nm (7.4 lbf ft)
S04054-11
cover

16.5 Refilling with coolant

Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.

Main work
– Make sure that screw 1 is tightened.
– Position the motorcycle upright.
– Pour coolant in up to measurement A above the radiator fins.
Guideline
Distance A above the radi- 10 mm (0.39 in)
ator fins

S04055-10 Coolant 0.95 l (1 qt.) Coolant ( p. 136)

– Mount the radiator cap.
– Go for a short test ride.
– Check the coolant level. ( p. 97)

98
 COOLING SYSTEM 16

Finishing work
– Fit the front spoiler. ( p. 54)

16.6 Changing the coolant

Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the
cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses
or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.

Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.

Condition
The engine is cold.
Preparatory work
– Remove the front spoiler. ( p. 54)
Main work
– Position the motorcycle upright.
– Place an appropriate container under the water pump cover.
– Remove screw 1. Take off radiator cap 2.
– Completely drain the coolant.

S04054-11

– Mount and tighten screw 1 with a new seal ring.

Guideline
Screw, water pump M6 10 Nm (7.4 lbf ft)
cover
– Pour coolant in up to measurement A above the radiator fins.
Guideline
Distance A above the radi- 10 mm (0.39 in)
S04055-10 ator fins

Coolant 0.95 l (1 qt.) Coolant ( p. 136)

– Mount the radiator cap.
– Go for a short test ride.
– Check the coolant level. ( p. 97)

99
16 COOLING SYSTEM

Finishing work
– Fit the front spoiler. ( p. 54)

100
 TUNING THE ENGINE 17

17.1 Checking the throttle cable play

– Check the throttle grip for smooth operation.
– Move the handlebar to the straight-ahead position. Turn the
throttle grip back and forth slightly and determine the play in
throttle cable A.
Throttle cable play 3 … 5 mm (0.12 … 0.2 in)
» If the throttle cable play does not meet specifications:
– Adjust the throttle cable play. ( p. 101)

400192-11
– Push the cold start button in all the way.
When the throttle grip is turned forward, the cold start but-
ton returns to its original position.
» If the cold start button does not return to its original posi-
tion:
– Adjust the throttle cable play. ( p. 101)

Danger
Danger of poisoning Exhaust gases are toxic and inhal-
ing them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation
when running the engine.
– Use effective exhaust extraction when starting or
running the engine in an enclosed space.

– Start the engine and let it run at idle speed. Move the handle-
bar to and fro over the entire steering range.
The idle speed must not change.
» If the idle speed changes:
– Adjust the throttle cable play. ( p. 101)

17.2 Adjusting the throttle cable play

Preparatory work
– Remove the tail section. ( p. 55)
– Take off the front rider's seat along with the fuel tank cover.
( p. 53)
– Remove the front spoiler. ( p. 54)
– Remove the trim along with the front. ( p. 56)
– Remove the fuel tank. ( p. 65)
– Check the throttle cable routing. ( p. 68)

101
17 TUNING THE ENGINE

Info
If the correct routing of the throttle cables has already been
secured, the fuel tank does not need to be removed.

Main work
– Move the handlebar to the straight-ahead position.
– Push back sleeve 1.
– Loosen nut 2.
– Turn adjusting screw 3 in as far as possible.
– Loosen nut 4.
– 6 all the way to the stop.
Push cold start button
– Turn adjusting screw 5 so that the cold start button moves to
the basic position when the throttle grip is turned to the front.
– Tighten nut 4.
– Turn adjusting screw 3 so that there is play in the throttle
cable at the throttle grip.
S04056-10 Guideline
Throttle cable play 3 … 5 mm (0.12 … 0.2 in)
– Tighten nut 2.
– Slide on sleeve1.
– Check the throttle grip for smooth operation.

17.3 Adjusting the idle speed

Warning
Danger of accidents The engine may go out spontaneously if the idle speed is set too low.
– Set the idle speed to the specified value. (Your authorized KTM workshop will be glad to help.)

Main work
– Run the engine until warm.
The cold start button is deactivated – The cold start but-
ton is in its basic position. ( p. 18)
– Take off the front rider's seat along with the fuel tank cover.
( p. 53)

Danger
S03974-10 Danger of poisoning Exhaust gases are toxic and inhal-
ing them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation
when running the engine.
– Use effective exhaust extraction when starting or
running the engine in an enclosed space.

– Adjust the idle speed by turning idle speed adjusting

screw 1 .
Guideline
Idle speed 2,300 ± 50 rpm

102
 TUNING THE ENGINE 17

Tachometer (45129075000)

Info
Turning counterclockwise lowers the idle speed.
Turning clockwise raises the idle speed.

Finishing work
– Mount the front rider's seat along with the fuel tank cover.
( p. 54)

17.4 Teaching the throttle valve position

Info
If the control unit detects that the throttle valve position at idle speed needs to be retaught, then the mal-
function indicator lamp flashes 2x per second.

Danger
Danger of poisoning Exhaust gases are toxic and inhal-
ing them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation
when running the engine.
– Use effective exhaust extraction when starting or
running the engine in an enclosed space.

– Allow the vehicle to run at idle speed.

The malfunction indicator lamp stops flashing once teach-
ing is completed.

Info
If the engine becomes too hot, perform a cool-down
ride at medium revs.
Then do not switch off the engine after this, but leave it
running at idle speed until teaching is completed.
S04074-01

17.5 Checking the basic position of the shift lever

Info
When driving, the shift lever must not touch the rider's boot when in the basic position.
When the shift lever keeps touching the boot, the transmission will be subject to an excessive load.

103
17 TUNING THE ENGINE

– Sit on the vehicle in the riding position and determine

distance Abetween the upper edge of your boot and the shift
lever.
Distance between shift lever 10 … 20 mm (0.39 …
and upper edge of boot 0.79 in)
» If the distance does not meet specifications:
– Adjust the shift lever. ( p. 104)

S03865-01

17.6 Adjusting the shift lever

Info
The adjustment range of the shift lever is limited.

– Loosen nut 1, holding threaded rod 2.

Info
1 has a left-handed thread.
Nut

– Loosen nut 3, holding threaded rod 2.

– Adjust the shift lever by turning shift rod 2.
Guideline
Shift rod adjustment 205 … 235 mm (8.07 …
range A 9.25 in)

Info
Make equal adjustments on both sides.
At least five screw threads must be screwed into the
seating.

– Check adjusting angle B.

Guideline
S03976-10 Adjusting angle B shift rod 97°
- bell crank - shift lever
– Tighten nut 3 while holding threaded rod 2.
Guideline
Nut, shift rod M6 10 Nm (7.4 lbf ft)
– Tighten nut 1 while holding threaded rod 2.
Guideline
Nut, shift rod M6LH 10 Nm (7.4 lbf ft)
– Check the shift lever to ensure it is functioning properly and
can move freely.

104
 TUNING THE ENGINE 17

17.7 Adjusting the quickshifter

Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.

Info
If the sensor or the cable is damaged, E1 flashes.
The installation position of the adjusting box must not be changed.

Condition
The quickshifter switch is in position 0.
Preparatory work
– Raise the motorcycle with the rear lifting gear. ( p. 40)
– Remove the tail section. ( p. 55)
Adjusting the shifting resistance:
– Start the engine.
– Press the right button.
15 is displayed.
– Press and hold both buttons until 15 flashes.
– Reduce shifting resistance with the left button or increase
with the right button.
Guideline
S04072-01 Adjustment range 1 … 40 kg (2 … 88 lb.)
Standard adjustment 15 kg

Info
The value 00 may not be set.

– Press both buttons for 3–5 seconds.

The indicator lights up and the value is stored.
– Release both buttons.
The indicator goes out.
– Switch off the engine.
Adjusting the ignition interruption time:
– Start the engine.
– Press and hold the left button, and then press and hold
both buttons until 30 is displayed.
The indicator jumps from t1 to t2 and then to 30.
When the button is released, the quickshifter must be
readjusted before the indicator displays 30.
– Press and hold the left button, and then press
and hold both buttons for 10 seconds until t1 is
displayed. Release both buttons and repeat the
step "Adjusting the ignition interruption time".
– Release both buttons and reduce the desired ignition inter-
ruption time with the left button, or increase it with the
right button.

105
17 TUNING THE ENGINE

Guideline
Adjustment range 10 … 99 ms
Standard adjustment 30 ms

Info
df corresponds to an ignition interruption time of
150 ms.

– Press and hold both buttons until the value no longer

flashes.
The ignition interruption time is adopted.
– Release both buttons.
The indicator goes out.
– Switch off the engine.
Programming shifting direction:
Condition
Engine is switched off.
– Engage second gear.
– Press and hold both buttons and start the engine with
the clutch pulled.
up flashes.
– With the engine running and the clutch pulled, shift
from second into third gear and press and hold the
shift lever until the indicator goes out.
Guideline
Standard adjustment Pull on the sensor for
shifting up
The standard adjustment must be retained as the
quickshifter is only appropriate for shifting up and
the shifting pattern cannot be changed.
When the indicator goes out, the adjustment is
stored.
– Shift the transmission into neutral and switch off the
engine.
Finishing work
– Install the tail section. ( p. 55)
– Remove the rear of the motorcycle from the lifting gear.
( p. 40)

106
 SERVICE WORK ON THE ENGINE 18

18.1 Changing the fuel screen

Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.

Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.

Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.

Preparatory work
– Remove the front spoiler. ( p. 54)
– Remove the trim along with the front. ( p. 56)
Main work
– Clean quick release coupling 1 thoroughly with compressed
air.

Info
Under no circumstances should dirt enter into the fuel
line. Dirt in the fuel line clogs the injection valve!

– Disconnect the quick release coupling.

Info
Remaining fuel may flow out of the fuel hose.

– Pull fuel screen 2 out of the connecting piece.

– Insert the new fuel screen all the way into the connecting
piece.
– Lubricate the O-ring and join the quick release coupling.

S04057-10

107
18 SERVICE WORK ON THE ENGINE

Danger
Danger of poisoning Exhaust gases are toxic and inhal-
ing them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation
when running the engine.
– Use effective exhaust extraction when starting or
running the engine in an enclosed space.

– Start the engine and check the response.

Finishing work
– Install the trim along with the front. ( p. 56)
– Fit the front spoiler. ( p. 54)

18.2 Checking the engine oil level

Info
The engine oil level can be checked when the engine is cold or warm.

Preparatory work
– Remove the front spoiler. ( p. 54)
– Stand the motorcycle upright on a horizontal surface.
Condition
The engine is cold.
– Check the engine oil level.

The engine oil reaches the middle of level viewer A.

» If the engine oil does not reach the middle of the level
viewer:
– Add engine oil. ( p. 111)
S04058-10
Condition
The engine is at operating temperature.
– Check the engine oil level.

Info
After switching off the engine, wait one minute
before checking the level.

The engine oil level is between the middle of the level

viewer A and the upper edge of the level viewer B.
» If the engine oil does not reach the middle of level
viewer A :
– Add engine oil. ( p. 111)
Finishing work
– Fit the front spoiler. ( p. 54)

108
 SERVICE WORK ON THE ENGINE 18

18.3 Changing the engine oil and oil filter, cleaning the oil screen

Warning
Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden.
– Wear suitable protective clothing and safety gloves.
– In the event of scalding, rinse the area affected immediately with lukewarm water.

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

Info
Drain the engine oil while the engine is at operating temperature.

Preparatory work
– Remove the front spoiler. ( p. 54)
– Park the motorcycle on a level surface.
Main work
– Position an appropriate container under the engine.
– Remove oil drain plug 1 with the magnet and seal ring.
Info
Do not remove screws 2.

S04059-10

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

– Allow the engine oil to drain completely.
– Thoroughly clean the parts and the sealing surfaces.

S04060-10

– Position oil screen 4 with the O-rings on a pin wrench.

– Position the pin wrench through the drill hole of the screw plug
in the opposite section of the engine case.
– Push the oil screen all the way into the engine case.

S04061-10

109
18 SERVICE WORK ON THE ENGINE

– Mount and tighten screw plug 3 with the O-ring.

Guideline
Screw plug, oil M20x1.5 15 Nm (11.1 lbf ft)
screen
– Mount and tighten oil drain plug 1 with the magnet and a
new seal ring.
Guideline

S04062-10
Oil drain plug with M12x1.5 20 Nm (14.8 lbf ft)
magnet

– Remove screws 5. Remove the oil filter cover with the O-ring.

S04063-10

– Pull oil filter 6 out of the oil filter housing.

Lock ring plier (51012011000)
– Allow the engine oil to drain completely.
– Thoroughly clean the parts and the sealing surfaces.

S04064-10

– Lay the motorcycle on its side and fill the oil filter housing to
about ⅓ full with engine oil.
– Fill the oil filter with engine oil and position the oil filter in the
housing.
– Oil the O-ring of the oil filter cover and mount it together with
oil filter cover 7
.
– Mount and tighten the screws.
Guideline
S04065-10 Screw, oil filter cover M6 10 Nm (7.4 lbf ft)
– Stand the motorcycle upright.
– Remove filler plug 8 with the O-ring, and fill up with engine
oil.
Engine oil 1.0 l (1.1 qt.) Engine oil
(SAE 10W/50)
( p. 136)

Info
Too little engine oil or poor-quality engine oil will result
S04066-10 in premature wear of the engine.

– Mount and tighten the filler plug together with the O-ring.

110
 SERVICE WORK ON THE ENGINE 18

Danger
Danger of poisoning Exhaust gases are toxic and inhal-
ing them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation
when running the engine.
– Use effective exhaust extraction when starting or
running the engine in an enclosed space.

– Start the engine and check for tightness.

Finishing work
– Check the engine oil level. ( p. 108)
– Fit the front spoiler. ( p. 54)

18.4 Adding engine oil

Info
Too little engine oil or poor-quality engine oil will result in premature wear of the engine.

– Remove filler plug 1 with the O-ring.

– Add the same engine oil used when the last oil change was
carried out.
Engine oil (SAE 10W/50) ( p. 136)

Info
For optimal performance of the engine oil, do not mix
different types of engine oil.
401955-10 We recommended changing the engine oil when neces-
sary.

– Mount and tighten the filler plug together with the O-ring.

Danger
Danger of poisoning Exhaust gases are toxic and inhal-
ing them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation
when running the engine.
– Use effective exhaust extraction when starting or
running the engine in an enclosed space.

– Start the engine and check for tightness.

111
19 CLEANING, CARE

19.1 Cleaning the motorcycle

Note
Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly.
The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc.
Pressure which is too high causes malfunctions and destroys components.
– Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
– Maintain a minimum distance between the nozzle of the pressure cleaner and the component.
Minimum clearance 60 cm (23.6 in)

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.

Info
Clean the motorcycle regularly to maintain its value and appearance over a long period.
Avoid direct sunshine when cleaning the motorcycle.

– Close off exhaust system to keep water from entering.

– Remove loose dirt first with a soft jet of water.
– Spray the heavily soiled parts with a normal commercial motor-
cycle cleaner and clean using a brush.
Motorcycle cleaner ( p. 138)

Info
Use warm water containing normal motorcycle cleaner
401061-01
and a soft sponge.
Never apply motorcycle cleaner to a dry motorcycle;
always rinse the vehicle with water first.

– After rinsing the motorcycle with a gentle spray of water, allow

it to dry thoroughly.
– Remove the closure of the exhaust system.

Warning
Danger of accidents Moisture and dirt impair the
brake system.
– Brake carefully several times to dry out and remove
dirt from the brake linings and the brake discs.

– After cleaning, ride the vehicle a short distance until the

engine warms up.

Info
The heat produced causes water at inaccessible loca-
tions in the engine and on the brake system to evapo-
rate.

– Push back the sleeves of the handlebar controls to allow any

water that has penetrated to evaporate.

112
 CLEANING, CARE 19

– After the motorcycle has cooled down, lubricate all moving

parts and pivot points.
– Clean the chain. ( p. 59)
– Treat bare metal (except for brake discs and the exhaust sys-
tem) with a corrosion inhibitor.
Preserving materials for paints, metal and rubber
( p. 138)
– Treat all painted parts with a mild paint care product.
Perfect finish and high gloss polish for paints ( p. 138)

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 product.
Special cleaner for glossy and matte paint finishes, metal
and plastic surfaces ( p. 139)
– Lubricate the ignition and steering lock.
Universal oil spray ( p. 139)

113
20 STORAGE

20.1 Storage

Info
If you plan to garage the motorcycle for a longer period, perform the following steps or have them per-
formed.
Before storing the motorcycle, check all parts for function and wear. If service, repairs, or replacements
are necessary, you should do this during the storage period (less workshop overload). In this way, you can
avoid long workshop waiting times at the start of the new season.

– When refueling for the last time before taking the motorcycle
out of service, add fuel additive.
Fuel additive ( p. 138)
– Refuel. ( p. 31)
– Clean the motorcycle. ( p. 112)
– Change the engine oil and oil filter, clean the oil screen.
( p. 109)
– Check the antifreeze and coolant level. ( p. 96)
401058-01
– Check tire pressure. ( p. 89)
– Remove the 12-V battery. ( p. 90)
– Charge the 12-V battery. ( p. 91)
Guideline
Storage temperature of the 0 … 35 °C (32 … 95 °F)
12-V battery without direct
sunlight
– Store vehicle in a dry location that is not subject to large fluc-
tuations in temperature.

Info
KTM recommends jacking up the motorcycle.

– Raise the motorcycle with the rear lifting gear. ( p. 40)

– Lift the motorcycle with the front lifting gear. ( p. 40)
– Cover the motorcycle with a tarp or cover that is permeable to
air.

Info
Do not use non-porous materials since they prevent
humidity from escaping, thus causing corrosion.
Avoid running the engine for a short time only. Since
the engine cannot warm up properly, the water vapor
produced during combustion condenses and causes
valves and the exhaust system to rust.

114
 STORAGE 20

20.2 Preparing for use after storage

– Take the motorcycle off the front lifting gear. ( p. 41)
– Remove the rear of the motorcycle from the lifting gear.
( p. 40)
– Install the 12-V battery. ( p. 91)
– Perform checks and maintenance measures when preparing for
use. ( p. 26)
– Take a test ride.

401059-01

115
21 TROUBLESHOOTING

Faults Possible cause Action

The engine does not turn when Operating error – Carry out start procedure. ( p. 26)
the start button is actuated 12-V battery discharged – Charge the 12-V battery. ( p. 91)
– Check the charging voltage.
– Check the open-circuit current.
– Check the stator winding of the alter-
nator.
Main fuse blown – Change the main fuse. ( p. 93)
Starter relay defective – Check the starter relay.
Starter motor defective – Check the starter motor.
The engine turns but does not Quick release coupling not – Join quick release coupling.
start joined
Fuel screen in the quick release – Change the fuel screen. ( p. 107)
coupling is clogged
Idle speed is not set correctly – Adjust the idle speed. ( p. 102)
Spark plug sooty or wet – Clean and dry the spark plug, or
change it if necessary.
Plug gap of spark plug too wide – Adjust plug gap.
Guideline
Spark plug electrode gap
0.8 mm (0.031 in)
Short-circuit cable in wiring – Check the wiring harness. (visual
harness frayed, switch-off but- check)
ton faulty – Check the electrical system.
Malfunction in the electronic – Read out the fault memory using the
fuel injection KTM diagnostics tool.
Engine does not speed up Malfunction in the electronic – Read out the fault memory using the
fuel injection KTM diagnostics tool.
Engine has too little power Air filter is very dirty – Clean the air filter and air filter box.
( p. 57)
Fuel filter is very dirty – Change the fuel filter.
Malfunction in the electronic – Read out the fault memory using the
fuel injection KTM diagnostics tool.
Exhaust system leaks, – Check exhaust system for damage.
deformed or too little glass – Change the glass fiber yarn filling of
fiber yarn filling in the main the main silencer. ( p. 64)
silencer
Valve clearance too little – Adjust the valve clearance.
The engine dies during the trip Lack of fuel – Refuel. ( p. 31)
Engine overheats Too little coolant in cooling sys- – Check the cooling system for leakage.
tem – Check the coolant level. ( p. 97)
Too little air stream – Switch off the engine when standing.
Radiator fins very dirty – Clean the radiator fins.
Foam formation in the cooling – Drain the coolant. ( p. 97)
system – Refill with coolant. ( p. 98)
Bent radiator hose – Change the radiator hose.
Misfiring while riding Quickshifter faulty – Switch off the quickshifter.

116
 TROUBLESHOOTING 21

Faults Possible cause Action

Malfunction indicator lamp Malfunction in the electronic – Check the wiring for damage and the
lights up or flashes fuel injection electrical plug-in connections for corro-
sion and damage.
– Read out the 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.
Engine oil level too high – Check the engine oil level. ( p. 108)
Engine oil too thin (low viscos- – Change the engine oil and oil filter,
ity) clean the oil screen. ( p. 109)
Piston or cylinder worn – Measure the piston/cylinder mounting
clearance.

117
22 BLINK CODE

Blink code for malfunction

indicator lamp
02a Malfunction indicator lamp flashes 2x per second
Error level condition Teaching of throttle valve position required

Blink code for malfunction

indicator lamp
02 Malfunction indicator lamp flashes 2x short
Error level condition Crankshaft speed sensor – circuit fault

Blink code for malfunction

indicator lamp
06 Malfunction indicator lamp flashes 6x short
Error level condition Throttle valve position sensor circuit A – circuit fault
Throttle valve position sensor circuit A – input signal too high

Blink code for malfunction

indicator lamp
09 Malfunction indicator lamp flashes 9x short
Error level condition Induction manifold pressure sensor – circuit fault
Induction manifold pressure sensor – input signal too low

Blink code for malfunction

indicator lamp
12 Malfunction indicator lamp flashes 1x long, 2x short
Error level condition Coolant temperature sensor – circuit fault
Coolant temperature sensor – input signal too low

Blink code for malfunction

indicator lamp
13 Malfunction indicator lamp flashes 1x long, 3x short
Error level condition Intake air temperature sensor – circuit fault
Intake air temperature sensor – input signal too low

Blink code for malfunction

indicator lamp
15 Malfunction indicator lamp flashes 1x long, 5x short
Error level condition Tilt sensor – input signal too low
Tilt sensor – input signal too high

Blink code for malfunction

indicator lamp
21 Malfunction indicator lamp flashes 2x long, 1x short
Error level condition Battery voltage – input voltage too high

Blink code for malfunction

indicator lamp
22 Malfunction indicator lamp flashes 2x long, 2x short
Error level condition Gear position sensor – circuit fault
Gear position sensor – input signal too high
Gear position sensor – malfunction

118
 BLINK CODE 22

Blink code for malfunction

indicator lamp
33 Malfunction indicator lamp flashes 3x long, 3x short
Error level condition Injection valve cylinder 1 – circuit fault

Blink code for malfunction

indicator lamp
37 Malfunction indicator lamp flashes 3x long, 7x short
Error level condition Ignition coil – circuit fault

Blink code for malfunction

indicator lamp
41 Malfunction indicator lamp flashes 4x long, 1x short
Error level condition Fuel pump controller – short circuit to ground/open circuit
Fuel pump controller – open circuit/short circuit to plus

Blink code for malfunction

indicator lamp
65 Malfunction indicator lamp flashes 6x long, 5x short
Error level condition EEPROM – malfunction

Blink code for malfunction

indicator lamp
Malfunction indicator lamp flashes continuously
Error level condition THREF – malfunction

119
23 TECHNICAL DATA

23.1 Engine
Design 1-cylinder 4-stroke engine, water-cooled
Displacement 249.91 cm³ (15.2505 cu in)
Stroke 52.3 mm (2.059 in)
Bore 78 mm (3.07 in)
Compression ratio 14.4:1
Idle speed 2,300 ± 50 rpm
Control DOHC, four valves controlled via cam lever, drive via
timing chain
Valve diameter, intake 32.5 mm (1.28 in)
Valve diameter, exhaust 26.5 mm (1.043 in)
Valve clearance
Intake at: 20 °C (68 °F) 0.08 … 0.15 mm (0.0031 … 0.0059 in)
Exhaust at: 20 °C (68 °F) 0.12 … 0.19 mm (0.0047 … 0.0075 in)
Crankshaft bearing 2 cylinder bearings
Conrod bearing Slide bearing
Piston pin bearing Bearing bush
Pistons Forged light alloy
Piston rings 1 compression ring, 1 oil scraper ring
Engine lubrication Pressure circulation lubrication with 2 trochoidal
pumps
Primary transmission 24:73
Clutch Multidisc clutch in oil bath/hydraulically activated
Gearbox 5-gear transmission, claw shifted
Transmission ratio
First gear 13:32
Second gear 16:32
Third gear 17:28
Fourth gear 19:26
Fifth gear 21:25
Alternator 12 V, 70 W
Ignition Contactless controlled fully electronic ignition with
digital ignition adjustment
Spark plug NGK LMAR9AI-8
Spark plug electrode gap 0.8 mm (0.031 in)
Cooling Water cooling, permanent circulation of coolant by
water pump
Starting aid Starter motor

120
 TECHNICAL DATA 23

23.2 Engine tightening torques

Nozzle, crank chamber ventilation M4 2 Nm (1.5 lbf ft)
Loctite®243™
Oil nozzle for alternator cooling M4 2 Nm (1.5 lbf ft)
Loctite®243™
Oil nozzle for balancer shaft lubri- M4 2 Nm (1.5 lbf ft)
cation Loctite®243™
Oil nozzle for clutch lubrication M4 2 Nm (1.5 lbf ft)
Loctite®243™
Oil nozzle for conrod bearing lubri- M4 2 Nm (1.5 lbf ft)
cation Loctite®243™
Oil nozzle for main bearing lubrica- M4 2 Nm (1.5 lbf ft)
tion Loctite®243™
Screw, oil nozzle for piston cooling M4 2.5 Nm (1.84 lbf ft)
Loctite®243™
Locking screw for bearing M5 6 Nm (4.4 lbf ft)
Loctite®243™
Oil channel screw plug in alterna- M5 2 Nm (1.5 lbf ft)
tor cover Loctite®243™
Oil nozzle for cam lever lubrication M5 3 Nm (2.2 lbf ft)
Loctite®243™
Oil nozzle, piston cooling M5 2 Nm (1.5 lbf ft)
Loctite®243™
Screw, bearing bolt, oil pump idler M5 6 Nm (4.4 lbf ft)
gear Loctite®243™
Screw, clutch spring retainer M5 6 Nm (4.4 lbf ft)
Screw, crankshaft speed sensor M5 6 Nm (4.4 lbf ft)
Loctite®243™
Screw, gear position sensor M5 5 Nm (3.7 lbf ft)
Loctite®243™
Screw, locking lever M5 6 Nm (4.4 lbf ft)
Loctite®243™
Screw, oil pump cover M5 6 Nm (4.4 lbf ft)
Loctite®243™
Screw, stator M5 6 Nm (4.4 lbf ft)
Loctite®243™
Nut, cylinder head M6 10 Nm (7.4 lbf ft)
Lubricated with engine oil
Nut, water pump impeller M6 6 Nm (4.4 lbf ft)
Loctite®243™
Screw, alternator cover M6 10 Nm (7.4 lbf ft)
Screw, clutch cover M6 10 Nm (7.4 lbf ft)
Screw, clutch slave cylinder M6 10 Nm (7.4 lbf ft)
Screw, engine case M6 10 Nm (7.4 lbf ft)
Screw, exhaust flange M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, guide rail M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, oil filter cover M6 10 Nm (7.4 lbf ft)

121
23 TECHNICAL DATA

Screw, shift drum locating M6 10 Nm (7.4 lbf ft)

Loctite®243™
Screw, shift lever M6 14 Nm (10.3 lbf ft)
Loctite®243™
Screw, starter motor M6 10 Nm (7.4 lbf ft)
Screw, timing chain failure protec- M6 10 Nm (7.4 lbf ft)
tion Loctite®243™
Screw, valve cover M6 8 Nm (5.9 lbf ft)
Screw, water pump cover M6 10 Nm (7.4 lbf ft)
Stud, cylinder head M6 10 Nm (7.4 lbf ft)
Screw, camshaft bearing bridge M7x1 Tightening sequence:
Tighten diagonally.
1st tightening stage
5 Nm (3.7 lbf ft)
2nd tightening stage
14 Nm (10.3 lbf ft)
Lubricated with engine oil
Crankshaft clamp screw plug M8 10 Nm (7.4 lbf ft)
Screw, tensioning rail M8 15 Nm (11.1 lbf ft)
Loctite®243™
Screw, engine sprocket M10 60 Nm (44.3 lbf ft)
Loctite®243™
Plug, oil channel M10x1 15 Nm (11.1 lbf ft)
Loctite®243™
Screw plug, cam lever axis M10x1 10 Nm (7.4 lbf ft)
Screw, rotor M10x1 70 Nm (51.6 lbf ft)
Collar and thread oiled / cone
degreased
Screw, unlocking of timing chain M10x1 8 Nm (5.9 lbf ft)
tensioner
Spark plug M10x1 12 Nm (8.9 lbf ft)
Coolant temperature sensor M10x1.25 12 Nm (8.9 lbf ft)
Nut, cylinder head M10x1.25 Tightening sequence:
Tighten diagonally.
1st tightening stage
10 Nm (7.4 lbf ft)
2nd tightening stage
30 Nm (22.1 lbf ft)
3rd tightening stage
180°
Stud, cylinder head M10x1.25 20 Nm (14.8 lbf ft)
Loctite®243™
Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft)
Screw plug, oil pressure control M12x1.5 20 Nm (14.8 lbf ft)
valve
Oil drain plug M14x1.5 15 Nm (11.1 lbf ft)
Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft)
Loctite®243™
Nut, primary gear wheel M18LHx1.5 120 Nm (88.5 lbf ft)
Loctite®243™
Screw plug, oil screen M20x1.5 15 Nm (11.1 lbf ft)

122
 TECHNICAL DATA 23

Plug, timing chain tensioner M24x1.5 40 Nm (29.5 lbf ft)

Screw, alternator cover M24x1.5 18 Nm (13.3 lbf ft)
Fixing nut for main bearing inner M27x1 60 Nm (44.3 lbf ft)
ring Loctite®243™

23.3 Capacities

23.3.1 Engine oil

Engine oil 1.0 l (1.1 qt.) Engine oil (SAE 10W/50)
( p. 136)

23.3.2 Coolant
Coolant 0.95 l (1 qt.) Coolant ( p. 136)

23.3.3 Fuel
Total fuel tank capacity, approx. 7 l (1.8 US gal) Super unleaded (ROZ 95/RON
95/PON 91) ( p. 137)

Fuel reserve, approx. 1.5 l (1.6 qt.)

23.4 Chassis
Frame Lattice frame of steel tubes, powder-coated
Fork WP Suspension APEX PRO 6535
Shock absorber WP Suspension XACT 5750
Brake system
front Disc brake with 4-piston brake caliper
rear Disc brake with single-pot brake caliper, floating
Suspension travel
front 120 mm (4.72 in)
rear 150 mm (5.91 in)
Brake discs - diameter
front 300 mm (11.81 in)
rear 220 mm (8.66 in)
Brake discs - wear limit
front 4.0 mm (0.157 in)
rear 3.6 mm (0.142 in)
Tire pressure (cold)
front 1.9 bar (28 psi)
rear 1.9 bar (28 psi)
Tire pressure (80° warm)
front 2.3 bar (33 psi)
rear 2.1 bar (30 psi)
Secondary ratio 17:37
Chain 1/2 x 3/16” (415)
Steering head angle 71.9°
Wheelbase 1,307 ± 15 mm (51.46 ± 0.59 in)

123
23 TECHNICAL DATA

Seat height, unloaded 820 mm (32.28 in)

Ground clearance, unloaded 135 mm (5.31 in)
Weight without fuel, approx. 95 kg (209 lb.)
Maximum permissible front axle load 93 kg (205 lb.)
Maximum permissible rear axle load 97 kg (214 lb.)
Maximum permissible overall weight 190 kg (419 lb.)

23.5 Electrical system

12-V battery HJTZ5S-FP-C Lithium-ion battery
Battery voltage: 12 V
Nominal capacity: 2.0 Ah
Maintenance-free
Fuse 067038485 7.5 A
Fuse 75011088010 10 A
Malfunction indicator lamp LED
Brake/tail light LED

23.6 Tires
Front tire Rear tire
90/80 R 17 54TL 115/75 R 17 66TL
Dunlop Racing KR 149 Radial Dunlop Racing KR 133 Radial
The tires specified represent one of the possible series production tires. Additional information is available in
the Service section under:
http://www.ktm.com

23.7 Fork
Fork article number 70354003
Fork WP Suspension APEX PRO 6535
Compression damping
Standard 10 clicks
Rebound damping
Standard 10 clicks
Spring preload - Preload Adjuster
Standard 25 clicks
Spring length with preload spacer(s) 225 mm (8.86 in)
Spring rate
Medium (standard) 6 N/mm (34 lb/in)
Fork length 660 mm (25.98 in)

Fork oil per fork leg 160 ml (5.41 fl. oz.) Fork oil (SAE 4) (48601166S1)
( p. 137)

124
 TECHNICAL DATA 23

23.8 Shock absorber

Shock absorber article number 18.18.7T.05
Shock absorber WP Suspension XACT 5750
Lowspeed compression damping
Standard 5 clicks
Highspeed compression damping
Standard 2 turns
Rebound damping
Standard 5 clicks
Spring preload 10 mm (0.39 in)
Spring rate
Weight of rider: 75 … 85 kg (165 … 187 lb.) 85 N/mm (485 lb/in)
Spring length 170 mm (6.69 in)
Gas pressure 10 bar (145 psi)
Fitted length 462 mm (18.19 in)

23.9 Chassis tightening torques

Screw, combination switch EJOT PT® K50x18 T20 2 Nm (1.5 lbf ft)
Screw, intake air temperature sen- EJOT DELTA PT® 45x12‑Z 0.7 Nm (0.52 lbf ft)
sor
Fitting, start button M3 0.4 Nm (0.3 lbf ft)
Fitting, switch-off button M3 0.4 Nm (0.3 lbf ft)
Fitting, inlet sleeve to throttle M4 5 Nm (3.7 lbf ft)
valve body
Screw, fixed grip M4 5 Nm (3.7 lbf ft)
Loctite®243™
Screw, service hour counter M4 0.8 Nm (0.59 lbf ft)
Remaining nuts, chassis M5 5 Nm (3.7 lbf ft)
Remaining screws, chassis M5 5 Nm (3.7 lbf ft)
Screw, battery terminal M5 2.5 Nm (1.84 lbf ft)
Screw, ground wire on frame M5 5 Nm (3.7 lbf ft)
Screw, shock absorber adjusting M5 5 Nm (3.7 lbf ft)
ring
Nut, cable on starter motor M6 4 Nm (3 lbf ft)
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft)
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Screw, bell crank shift lever M6 6.5 Nm (4.79 lbf ft)
Screw, chain sliding guard M6 6 Nm (4.4 lbf ft)
Loctite®243™
Screw, front brake disc M6 14 Nm (10.3 lbf ft)
Loctite®243™
Screw, handlebar stub M6 Tightening sequence:
Tighten top first, then bottom.
10 Nm (7.4 lbf ft)
Loctite®243™

125
23 TECHNICAL DATA

Screw, rear brake disc M6 14 Nm (10.3 lbf ft)

Loctite®243™
Screw, steering damper clamp M6 10 Nm (7.4 lbf ft)
Screw, throttle grip M6 5 Nm (3.7 lbf ft)
Fuel connection on fuel tank M8 15 Nm (11.1 lbf ft)
Remaining nuts, chassis M8 25 Nm (18.4 lbf ft)
Remaining screws, chassis M8 25 Nm (18.4 lbf ft)
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
Screw, chain sliding piece M8 15 Nm (11.1 lbf ft)
Screw, engine brace on engine M8x20 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, engine brace on frame M8x15 25 Nm (18.4 lbf ft)
Loctite®2701™
Screw, footrest bracket M8 30 Nm (22.1 lbf ft)
Loctite®2701™
Screw, fork stub M8 15 Nm (11.1 lbf ft)
Screw, manifold on cylinder head M8 15 Nm (11.1 lbf ft)
bolt
Screw, subframe bottom M8 30 Nm (22.1 lbf ft)
Loctite®2701™
Screw, subframe top M8 35 Nm (25.8 lbf ft)
Loctite®2701™
Screw, top steering stem M8 20 Nm (14.8 lbf ft)
Loctite®243™
Screw, top triple clamp M8 12 Nm (8.9 lbf ft)
Engine bracket screw M10 60 Nm (44.3 lbf ft)
Remaining nuts, chassis M10 45 Nm (33.2 lbf ft)
Remaining screws, chassis M10 45 Nm (33.2 lbf ft)
Screw, bottom shock absorber M10 60 Nm (44.3 lbf ft)
Loctite®2701™
Screw, front brake caliper M10 45 Nm (33.2 lbf ft)
Loctite®243™
Screw, top shock absorber M10 60 Nm (44.3 lbf ft)
Loctite®2701™
Rear sprocket bolt M10x1.25 50 Nm (36.9 lbf ft)
Loctite®243™
Nut, fuel pump M12 15 Nm (11.1 lbf ft)
Nut, angle lever to link fork M14x1.5 60 Nm (44.3 lbf ft)
Nut, frame on linkage lever M14x1.5 60 Nm (44.3 lbf ft)
Nut, linkage lever on angle lever M14x1.5 60 Nm (44.3 lbf ft)
Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft)
Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft)
Screw, steering head, top M20x1.5 12 Nm (8.9 lbf ft)
Screw-in fitting, cooling system M24x1.5 15 Nm (11.1 lbf ft)
Loctite®243™
Screw, front wheel spindle M50 50 Nm (36.9 lbf ft)

126
TECHNICAL DATA 23

127
24 WIRING DIAGRAM

24.1 Page 1 of 4

S04077-01

128
 WIRING DIAGRAM 24

Components:
A11 EFI control unit
C10 Capacitor
S21 Start button
M10 Electric starter system
K19 Starter relay
G10 12-V battery
T20 Voltage regulator
G20 Alternator
K30 Power relay

129
24 WIRING DIAGRAM

24.2 Page 2 of 4

S04078-01

130
 WIRING DIAGRAM 24

Components:
A11 EFI control unit
S20 Switch-off button
F1 Fuse
R30 CAN bus
P25 Malfunction indicator lamp
M51 Injection valve
M13 Fuel pump

131
24 WIRING DIAGRAM

24.3 Page 3 of 4

S04079-01

132
 WIRING DIAGRAM 24

Components:
A11 EFI control unit
B43 Throttle valve position sensor
S55 Map Select switch
B41 Induction manifold pressure sensor
B21 Coolant temperature sensor
R51 Ignition coil
B37 Crankshaft speed sensor
B26 Tilt sensor
B12 Intake air temperature sensor
B34 Gear position sensor

133
24 WIRING DIAGRAM

24.4 Page 4 of 4

S04080-01

134
 WIRING DIAGRAM 24

Components:
P10 Combination instrument
A40 Quick shifter control unit
B27 Shift shaft sensor
S57 Quickshift switch
P37 Tail light
S56 Tail light switch
B22 Coolant temperature sensor

135
25 SUBSTANCES

Brake fluid DOT 4 / DOT 5.1

Standard/classification
– DOT
Guideline
– Use only brake fluid that complies with the specified standard (see specifications on the container) and that
exhibits the corresponding properties.
Recommended supplier
Castrol
– REACT PERFORMANCE DOT 4
MOTOREX®
– Brake Fluid DOT 5.1

Coolant
Guideline
– Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors. Low grade
and unsuitable antifreeze causes corrosion, deposits and frothing.
– Do not use pure water as only coolant is able to meet the requirements needed in terms of corrosion protec-
tion and lubrication properties.
– Only use coolant that complies with the requirements stated (see specifications on the container) and that
has the relevant properties.
Antifreeze protection to at least −25 °C (−13 °F)

The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant needs
to be diluted.

The use of premixed coolant is recommended.

Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility)
with other coolants.

Recommended supplier
MOTOREX®
– COOLANT M3.0

Engine oil (SAE 10W/50)

Standard/classification
– JASO T903 MA2 ( p. 140)
– SAE ( p. 140) (SAE 10W/50)
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that
possess the corresponding properties.
Fully synthetic engine oil
Recommended supplier
MOTOREX®
– Cross Power 4T

136
 SUBSTANCES 25

Fork oil (SAE 4) (48601166S1)

Standard/classification
– SAE ( p. 140) (SAE 4)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit
the corresponding properties.

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

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.

Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15,
E25, E85, E100).

137
26 AUXILIARY SUBSTANCES

Air filter cleaner

Recommended supplier
MOTOREX®
– Racing Bio Dirt Remover

Chain cleaner
Recommended supplier
MOTOREX®
– Chain Clean

Fuel additive
Recommended supplier
MOTOREX®
– Fuel Stabilizer

High viscosity grease

Recommended supplier
SKF®
– LGHB 2

Long-life grease
Recommended supplier
MOTOREX®
– Bike Grease 2000

Motorcycle cleaner
Recommended supplier
MOTOREX®
– Moto Clean

Oil for foam air filter

Recommended supplier
MOTOREX®
– Racing Bio Liquid Power

Perfect finish and high gloss polish for paints

Recommended supplier
MOTOREX®
– Moto Shine

Preserving materials for paints, metal and rubber

Recommended supplier
MOTOREX®
– Moto Protect

138
 AUXILIARY SUBSTANCES 26

Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
Recommended supplier
MOTOREX®
– Quick Cleaner

Street chain spray

Guideline
Recommended supplier
MOTOREX®
– Chainlube Road Strong

Universal oil spray

Recommended supplier
MOTOREX®
– Joker 440 Synthetic

139
27 STANDARDS

JASO T903 MA2

Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2
standard.
Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor-
cycle specification.
Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high
performance at high engine speeds.
In most motorcycle engines, the transmission and clutch are lubricated with the same oil.
The JASO T903 MA2 standard meets these special requirements.

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

140
 INDEX OF SPECIAL TERMS 28

- Launch control Vehicles electronics functions for achieving the best

possible acceleration from a standing position
OBD On-board diagnosis Vehicle system, which monitors the specified parame-
ters of the vehicle electronics

141
29 LIST OF ABBREVIATIONS

Art. no. Article number

ca. circa
cf. compare
e.g. for example
etc. et cetera
i.a. inter alia
no. number
poss. possibly

142
 LIST OF SYMBOLS 30

30.1 Yellow and orange symbols

Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are
also represented by yellow or orange symbols.
Malfunction indicator lamp lights up/flashes orange – The OBD has detected a malfunction in
the vehicle electronics.
Malfunction indicator lamp flashes orange rapidly – Launch control is activated.

143
INDEX

fluid, changing . . . . . . . . . . . . . . . . . . . . . . 70
INDEX

1 Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
12-V battery basic position, adjusting . . . . . . . . . . . . . . . 72
charging . . . .... . . . . . . . . . . . . . . . . . . . 91 Cold start button . . . . . . . . . . . . . . . . . . . . . . . . 18
installing . . . .... . . . . . . . . . . . . . . . . . . . 91
Combination instrument
removing . . . .... . . . . . . . . . . . . . . . . . . . 90
overview . . . . . . . . . . . . . . . . . . . . . . . . . . 20
starting power ... . . . . . . . . . . . . . . . . . . . 25
Coolant
A
antifreeze and coolant level, checking . . . . . . 96
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 draining . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Air filter level, checking . . . . . . . . . . . . . . . . . . . . . . 97
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 57 refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . 96
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Customer service . . . . . . . . . . . . . . . . . . . . . . . . 9
Air filter box
D
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Diagnostics connector . . . . . . . . . . . . . . . . . . . . 95
Antifreeze
E
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Auxiliary substances . . . . . . . . . . . . . . . . . . . . . . 9 Engine
running in . . . . . . . . . . . . . . . . . . . . . . . . . 25
B
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . 12
Blink code . . . . . . . . . . . . . . . . . . . . . . . . 118-119
Engine oil
Brake discs
adding . . . . . . . . . . . . . . . . . . . . . . . . . . 111
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 73
changing . . . . . . . . . . . . . . . . . . . . . . . . . 109
Brake fluid
Engine oil level
of front brake, adding . . . . . . . . . . . . . . . . . 74
checking . . . . . . . . . . . . . . . . . . . . . . . . . 108
of rear brake, adding . . . . . . . . . . . . . . . . . . 78
Engine sprocket
Brake fluid level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 61
of front brake, checking . . . . . . . . . . . . . . . . 73
of rear brake, checking . . . . . . . . . . . . . . . . 78 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Brake linings F
front brake, checking . . . ... . . . . . . . . . . . 75 Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
of front brake, changing . ... . . . . . . . . . . . 75 Filling up
of the rear brake, changing .. . . . . . . . . . . . 80 fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
rear brake, checking . . . . ... . . . . . . . . . . . 80
Foot brake lever . . . . . . . . . . . . . . . . . . . . . . . . 19
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 basic position, adjusting . . . . . . . . . . . . . . . 82
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 free travel, adjusting . . . . . . . . . . . . . . . . . . 83
C free travel, checking . . . . . . . . . . . . . . . . . . 83
resistance, adjusting . . . . . . . . . . . . . . . . . . 84
Capacity
coolant . . . . . . . . . . . . . . . . . . . . . 98-99, 123 Fork
engine oil . . . . . . . . . . . . . . . . . . . . 110, 123 compression damping, adjusting . . . . . . . . . . 35
fuel . . . . . . . . . . . . . . . . . . . . . . . . . 32, 123 rebound, adjusting . . . . . . . . . . . . . . . . . . . 35
spring preload, adjusting . . . . . . . . . . . . . . . 36
Chain
chain dirt accumulation, checking . . . . . . . . 58 Fork article number . . . . . . . . . . . . . . . . . . . . . . 12
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Fork legs
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 59 installing . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Chain tension removing . . . . . . . . . . . . . . . . . . . . . . . . . . 42
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Frame
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 59 checking . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Clutch Front fender
fluid level, checking/correcting . . . . . . . . . . . 69 installing . . . . . . . . . . . . . . . . . . . . . . . . . . 53

144
 INDEX

removing . . . . . . . . . . . . . . . . . . . . . . . . . . 52 installing . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Front rider’s seat removing . . . . . . . . . . . . . . . . . . . . . . . . . . 62
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Manufacturer warranty . . . . . . . . . . . . . . . . . . . . . 9
Front rider's seat with the fuel tank cover Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
mounting . . . . . . . . . . . . . . . . . . . . . . . . . 54 Motorcycle
Front spoiler cleaning . . . . . . . . . . . . . . . . .. . . . . . . . 112
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 54 from lift stand, removing . . . . . .. . . . . . . . . 42
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 54 lift stand, raising with . . . . . . . .. . . . . . . . . 41
lifting with front lifting gear . . . .. . . . . . . . . 40
Front wheel
raising with lifting gear at rear . .. . . . . . . . . 40
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 85
removing from lifting gear at rear . . . . . . . . . 40
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 85
taking off front lifting gear . . . . .. . . . . . . . . 41
Fuel screen
changing . . . . . . . . . . . . . . . . . . . . . . . . . 107 O

Fuel tank Oil filter

installing . . . . . . . . . . . . . . . . . . . . . . . . . . 66 changing . . . . . . . . . . . . . . . . . . . . . . . . . 109
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Oil screen
Fuel tank filler cap cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 109
closing . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Owner's Manual . . . . . . . . . . . . . . . . . . . . . . . . . 8
opening . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 P
Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fuse Plug-in stand . . . . . . . . . . . . . . . . . . . . . . . . . . 19
main fuse, changing . . . . . . . . . . . . . . . . . . 93 Preparing for use
of individual power consumers, changing . . . . 94 advice on preparing for first use . . . . . . . . . . 24
H after storage . . . . . . . . . . . . . . . . . . . . . . 115
checks and maintenance measures when
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . 13
preparing for use . . . . . . . . . . . . . . . . . . . . 26
basic position, adjusting . . . . . . . . . . . . . . . 78
Protective clothing . . . . . . . . . . . . . . . . . . . . . . . 7
I
Q
Idle speed
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 102 Quickshifter . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 105
Idle speed adjusting screw . . . . . . . . . . . . . . . . . 18
Implied warranty . . . . . . . . . . . . . . . . . . . . . . . . . 9 Quickshifter switch . . . . . . . . . . . . . . . . . . . . . . 14

Indicator lamp R
overview . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Rear sprocket
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 checking . . . . . . . . . . . . . . . . . . . . . . . . . . 61
L Rear wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Launch control
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 86
activating . . . . . . . . . . . . . . . . . . . . . . . . . 27
Riding
Link fork
starting off . . . . . . . . . . . . . . . . . . . . . . . . 28
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Rubber grips
Lower triple clamp
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 69
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 45
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 45 S
Safe operation . . . . . . . . . . . . . . . . . . . . . . .... 7
M
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 9
Main fuse Service hour counter . . . . . . . . . . . . . . . . . . . . . 15
changing . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Service schedule . . . . . . . . . . . . . . . . . . . . . 33-34
Main silencer Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
glass fiber yarn filling, changing . . . . . . . . . . 64 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 104

145
INDEX

basic position, checking . . . . . . . . . . . . . . 103 Tire pressure

Shock absorber checking . . . . . . . . . . . . . . . . . . . . . . . . . . 89
compression damping, general . . . . . . . . . . . 37 Traction control
high-speed compression damping, adjusting . . 38 activating . . . . . . . . . . . . . . . . . . . . . . . . . 28
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . 31
low-speed compression damping, adjusting . . 38
Trim
rebound damping, adjusting . . . . . . . . . . . . . 39
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 56
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 49
spring preload, adjusting . . . . . . . . . . . . . . . 36 Trim with front
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Shock absorber article number . . . . . . . . . . . . . . 12
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Troubleshooting . . . . . . . . . . . . . . . . . . . . 116-117
Start button . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 U
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Use definition .......................... 6
Starting power of lithium-ion batteries at low tempera-
tures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 V
Vehicle identification number . . . . . . . . . . . . . . . 12
Steering damper . . . . . . . . . . . . . . . . . . . . . . . . 16
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 16 View of vehicle
front left . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Steering head bearing
rear right . . . . . . . . . . . . . . . . . . . . . . . . . . 11
lubricating . . . . . . . . . . . . . . . . . . . . . . . . . 49
Steering head bearing play W
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Wiring diagram
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Page 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . 128
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Page 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . 130
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Page 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . 132
Switch-off button . . . . . . . . . . . . . . . . . . . . . . . 13 Page 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . 134

T Work rules ............................ 8

Tail light switch . . . . . . . . . . . . . . . . . . . . . . . . 14

Tail section
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 55
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Technical data
capacities . . . . . . . . . . . . . . . . . . . . . . . . 123
chassis . . . . . . . . . . . . . . . . . . . . . . . . . . 123
chassis tightening torques . . . . . . . . . . . . . 125
electrical system . . . . . . . . . . . . . . . . . . . 124
engine . . . . . . . . . . . . . . . . . . . . . . . . . . 120
engine tightening torques . . . . . . . . . . . . . 121
fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
shock absorber . . . . . . . . . . . . . . . . . . . . . 125
tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Throttle cable play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 101
checking . . . . . . . . . . . . . . . . . . . . . . . . . 101
Throttle cable routing
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Throttle grip . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Throttle valve position
teaching . . . . . . . . . . . . . . . . . . . . . . . . . 103
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 88

146
*3214169en*
3214169en

01/2020

KTM Sportmotorcycle GmbH

5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM
http://www.ktm.com