KTM 690 Duke 2009 Manual UK

OWNER'S MANUAL 2009
690 DUKE EU
690 DUKE AUS/UK
690 DUKE JP
ART. NO. 3211370en
DEAR KTM CUSTOMER 1
Congratulations on your decision to buy a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you
DEAR KTM CUSTOMER
enormous pleasure if you service and maintain it accordingly.
We wish you great pleasure riding the vehicle!
Enter the serial numbers of your vehicle below.

Chassis number/type label ( p. 16) Dealer's stamp
Engine number ( p. 17)
Key number ( p. 16)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing devel-
opment and design of our motorcycles cannot however be completely excluded.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications,
prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these
to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options,
deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment
that does not belong to the regular scope of delivery.
DEAR KTM CUSTOMER 2
© 2008 by KTM-Sportmotorcycle AG, Mattighofen Austria

All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
CONTENTS 3
Setting the clock .............................................................. 28

CONTENTS
MEANS OF REPRESENTATION ............................................... 6

IMPORTANT NOTES ............................................................... 7 Combination instrument - display ODO ............................... 29
VIEW OF VEHICLE................................................................ 12 Combination instrument - setting/resetting TRIP 1............... 29
View of vehicle, front left side............................................ 12 Combination instrument - setting/resetting TRIP 2............... 30
View of vehicle, rear right .................................................. 14 Combination instrument - TRIP F display............................ 31
LOCATION OF SERIAL NUMBERS ......................................... 16 Combination instrument - coolant temperature indicator ...... 31
Chassis number/type label ................................................. 16 Opening filler cap ............................................................. 32
Key number ..................................................................... 16 Closing filler cap .............................................................. 32
Engine number................................................................. 17 Fuel taps ......................................................................... 33
Fork part number.............................................................. 17 Handrails......................................................................... 33
Shock absorber part number.............................................. 18 Seat lock ......................................................................... 34
CONTROLS .......................................................................... 19 Owner's manual................................................................ 34
Clutch lever ..................................................................... 19 Tool set ........................................................................... 35
Hand brake lever .............................................................. 19 Passenger footrests........................................................... 35
Light switch ..................................................................... 20 Shift lever........................................................................ 36
Headlight flasher switch.................................................... 20 Foot brake pedal .............................................................. 37
Flasher switch .................................................................. 21 Side stand ....................................................................... 37
Horn button ..................................................................... 21 GENERAL TIPS AND HINTS ON PUTTING INTO
Ignition/steering lock ........................................................ 22 OPERATION......................................................................... 38
Emergency OFF switch...................................................... 22 Advice on first use ............................................................ 38
Electric starter button ....................................................... 23 Running in the engine....................................................... 39
Combination instrument .................................................... 23 Loading the vehicle .......................................................... 40
Combination instrument - function buttons ......................... 24 RIDING INSTRUCTIONS ....................................................... 42
Combination instrument - tachometer................................. 24 Checks before putting into operation .................................. 42
Combination instrument - indicator lamps........................... 25 Starting ........................................................................... 43
Combination instrument - display....................................... 26 Starting up ...................................................................... 45
Combination instrument - speedometer............................... 27 Shifting, riding ................................................................. 45
Setting kilometers or miles ................................................ 27 Braking ........................................................................... 48
Combination instrument - time .......................................... 28 Stopping, parking ............................................................. 49
CONTENTS 4
Refueling......................................................................... 51 Adding front brake fluid x............................................... 72

SERVICE SCHEDULE............................................................ 53 Checking the front brake linings......................................... 73
Important maintenance work to be carried out by an Checking free play of foot brake lever ................................. 74
authorized KTM workshop. ................................................ 53 Checking rear brake fluid level........................................... 75
Important maintenance work to be carried out by an Adding rear brake fluid x ................................................ 76
authorized KTM workshop. (as additional order)................... 55
Checking the rear brake linings .......................................... 77
MAINTENANCE WORK ON CHASSIS AND ENGINE ................. 56
Removing front wheel x .................................................. 78
Jacking up front of motorcycle ........................................... 56
Installing the front wheel x .............................................. 79
Taking front from work stand ............................................. 56
Removing rear wheel .................................................... 80
x
Jacking up rear of motorcycle ............................................ 57
Installing the rear wheel x ............................................... 81
Taking the rear from the workstand .................................... 57
Fork/shock absorber .......................................................... 58 Checking the rear hub rubber dampers x .......................... 83
Adjusting the compression damping of the fork ................... 58 Checking the tire condition................................................ 84
Adjusting the rebound damping of the fork.......................... 59 Checking tire air pressure .................................................. 85
Compression damping of the shock absorber ....................... 60 Removing the seat ............................................................ 86
Adjusting the low-speed compression damping of the shock Mounting the seat ............................................................ 87
absorber .......................................................................... 60 Reinstalling the fuel tank .................................................. 87
Adjusting the high-speed compression damping of the Positioning the fuel tank ................................................... 88
shock absorber ................................................................. 61 Removing the battery x................................................... 89
Adjusting the rebound damping of the shock absorber.......... 62 Installing the battery .................................................... 91
x
Bleeding the fork legs ....................................................... 63 Recharging the battery x ................................................. 93
Checking chain dirt .......................................................... 64 Changing the main fuse .................................................... 95
Cleaning the chain............................................................ 64 Changing the fuses of power consumers.............................. 96
Checking the chain tension ............................................... 65 Adjusting the engine characteristic..................................... 98
Adjusting the chain tension ............................................... 66 Removing headlight mask with headlight .......................... 100
Checking rear sprocket / engine sprocket for wear ................ 68 Installing the headlight mask with the headlight ................ 102
Checking chain wear ......................................................... 69 Changing the low beam bulb............................................ 103
Checking brake discs ........................................................ 70 Change the high beam bulb............................................. 106
Adjusting basic position of handbrake lever......................... 71 Changing the parking light bulb ....................................... 108
Checking the front brake fluid level .................................... 71 Changing the flasher bulb ............................................... 109
CONTENTS 5
Checking the low beam headlight adjustment.................... 110 STORAGE .......................................................................... 145
Checking the high beam headlight adjustment .................. 111 Storage.......................................................................... 145
Adjusting the light range of the low beam headlight ........... 112 Putting into operation after storage .................................. 146
Adjusting the light range of the high beam headlight ......... 113 TECHNICAL DATA - ENGINE ............................................... 147
Cooling system ............................................................... 115 Capacity - engine oil ....................................................... 148
Checking antifreeze and coolant level ............................... 115 Capacity - coolant........................................................... 148
Checking the coolant level............................................... 118 TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 149
Draining the coolant x .................................................. 119 TECHNICAL DATA - CHASSIS ............................................. 152
Filling/bleeding the cooling system x .............................. 120 Lighting equipment ........................................................ 153
Adjusting basic position of clutch lever............................. 122 Capacity - fuel................................................................ 154
Checking/rectifying the fluid level of the hydraulic clutch ... 123 TECHNICAL DATA - FORK................................................... 155
Checking play in gas Bowden cable .................................. 124 TECHNICAL DATA - SHOCK ABSORBER .............................. 156
Adjusting the play in the gas Bowden cable x .................. 125 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ......... 158
Checking engine oil level................................................. 125 SUBSTANCES.................................................................... 162
Changing the engine oil and filter, cleaning the oil AUXILIARY SUBSTANCES................................................... 166
screens .....................................................................
x 126 STANDARDS...................................................................... 168
Draining the engine oil x ............................................... 126 INDEX ............................................................................... 169
Removing the oil filter x ................................................ 127
Installing the oil filter x ................................................ 129
Cleaning the oil screens x ............................................. 129
Filling up with engine oil x ............................................ 131
Adding engine oil ........................................................... 132
TROUBLESHOOTING.......................................................... 134
FLASHING CODE ............................................................... 137
CLEANING......................................................................... 142
Cleaning motorcycle ....................................................... 142
PROTECTION FOR WINTER OPERATION.............................. 144
Conservation for winter operation ..................................... 144
MEANS OF REPRESENTATION 6
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 done in an authorized KTM workshop! There, your motorcycle will be serviced optimally
by specially trained experts using the specialist tools required.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained in the following.
Specific name Identifies a proprietary name.
Name® Identifies a protected name.
Brand™ Identifies a trademark.

IMPORTANT NOTES 7
Use definition
KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race
courses or offroad.
Info
The motorcycle is authorized for public road traffic in the homologous version only.
Maintenance
A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in
the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of
components.
Using the motorcycle in extreme conditions such as very muddy or wet roads can lead to above-average wear of components such as the
transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the ser-
vice schedule is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will
ensure a much longer service life for your motorcycle.
Warranty
The work prescribed in the service plan must only be carried out in an authorized KTM workshop and confirmed in the service record; oth-
erwise all warranty claims will be disregarded. No warranty claim can be met for damage resulting from manipulation and/or other changes
to the vehicle.
Fuel, oils, etc.

You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
IMPORTANT NOTES 8
Spare parts, accessories

In the interests of your own safety, use only spare parts and accessories approved and/or recommended by KTM, and have these fitted in
an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
Work rules
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced
by new parts.
If a thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific advice on its usage.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Following repairs or servicing, the vehicle must be checked for roadworthiness.
Transport
Note
Danger of damage The parked vehicle can roll away or fall over.
– Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components get very hot when the machine is driven.
– Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is still warm
from being run. Always let the vehicle cool first.
– Switch off the engine and remove the ignition key.

– Use straps or other suitable devices to secure the motorcycle against accidents or falling over.
IMPORTANT NOTES 9
Environment
Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential
problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that
such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle
legally, display environmental consciousness, and respect the rights of others.
Notes/warnings
Pay close attention to the notes/warning.
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing,
you or others may not recognize dangers and may therefore be injured.
IMPORTANT NOTES 10
Grades of risks
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 will possibly lead to light injury 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.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Owner's manual
– It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful information
and tips to help you operate and handle your motorcycle. Only then will you find out how to customize the motorcycle ideally for your
own use and how you can protect yourself from injury. The owner's manual also contains important information on servicing the motor-
cycle.
– The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.
11
VIEW OF VEHICLE 12
View of vehicle, front left side

3.1
700132-01
VIEW OF VEHICLE 13
1 Combination instrument
2 Rear mirror
3 Clutch lever
4 Seat
5 Handrail
6 Front brake caliper
7 Left fuel tap
8 Shift lever
9 Engine number
10 Side stand
VIEW OF VEHICLE 14
View of vehicle, rear right

3.2
700133-01
VIEW OF VEHICLE 15
1 Seat lock
2 Light switch, headlight flasher switch, indicator switch, horn button
3 Filler cap
4 Emergency OFF switch, electric starter button
5 Hand brake lever
6 Chassis number, type label
7 Rear brake caliper
8 Passenger footrests
9 Map‑Select switch
10 Foot brake pedal
11 Level viewer, engine oil
12 Right fuel tap
LOCATION OF SERIAL NUMBERS 16
Chassis number/type label

4.1
The chassis number  is stamped on the right of the steering head.

The type label  is on the right of the frame behind the steering head.
500006-01
Key number
4.2
The key number  can be found on the KEYCODECARD.
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.
100179-10
Engine number
4.3
The engine number  is stamped on the left side of the engine under the engine sprocket.
700125-01
Fork part number

4.4
The fork part number  is stamped on the inner side of the fork stub.
700126-01
Shock absorber part number

4.5
The shock absorber part number  is stamped on the top of the shock absorber above the
adjusting ring toward the rear.
700128-01
CONTROLS 19
Clutch lever
5.1
The clutch lever  is fitted on the left side of the handlebar.

The clutch is hydraulically operated and self-adjusting.
100114-10
Hand brake lever

5.2
The hand brake lever  is fitted on the right side of the handlebar.
The front brake is engaged using the hand brake lever.
500018-01
CONTROLS 20
Light switch
5.3
The light switch  is fitted on the left side of the handlebar.

Possible states
Low beam on – Light switch is turned downwards. In this position, the low
beam and tail light are switched on.
High beam on – Light switch is turned upwards. In this position, the high
beam and the tail light are switched on.
500020-01
Headlight flasher switch

5.4
The headlight flasher switch  is fitted on the left side of the handlebar.
Possible states
• Headlight flasher switch in neutral position
• Headlight flasher switch pressed – In this position, the headlight flasher (high beam)
is actuated.
500020-11
CONTROLS 21
Flasher switch
5.5
The flasher switch  is fitted on the left side of the handlebar.

Possible states
Flasher light off
Flasher light, left, on – Flasher switch pressed to the right. The flasher
switch returns automatically to the central position after use.
Flasher light, right, on – Flasher switch pressed to the right. The flasher
switch returns automatically to the central position after use.
500021-10 To switch off the flasher light, press the flasher switch towards the switch case.
Horn button
5.6
The horn button  is fitted on the left side of the handlebar.

Possible states
• Horn button in neutral position
• Horn button pressed – The horn is operated in this position.
500021-11
CONTROLS 22
Ignition/steering lock
5.7
The ignition/steering lock  is in front of the upper triple clamp.

Possible states
Ignition OFF – In this position, the ignition circuit is interrupted, a running
engine stops, and a non-running engine will not start. The ignition key can
be removed.
Ignition ON – In this position, the ignition circuit is closed and the engine
can be started.
Steering locked – In this position, the ignition circuit is interrupted and the
600825-01 steering locked. The ignition key can be removed.
Emergency OFF switch

5.8
The emergency OFF switch  is fitted on the left side of the handlebar.
Possible states
Emergency OFF switch off – In this position, the ignition circuit is inter-
rupted, a running engine stops, and the engine cannot be started.
Emergency OFF switch on – This position is necessary for operation as the

ignition circuit is closed.
500022-10
CONTROLS 23
Electric starter button

5.9
The electric starter button  is fitted on the right side of the handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button pressed – In this position, the electric starter is actuated.
500022-11
Combination instrument
5.10
The combination instrument is installed in front of the handlebar.

The combination instrument is divided into 4 function areas.
 Function buttons
 Tachometer
 Indicator lights
 Display
700116-01
CONTROLS 24
Combination instrument - function buttons

5.11
You can change the display mode with the MODE button .
Possible display modes are distance traveled (ODO), trip master 1 (TRIP 1) and trip mas-
ter 2 (TRIP 2).
Press the SET button  to reset the trip master 1 function (TRIP 1) and trip master 2 func-
tion (TRIP 2) to 0.0.
Button  has no function.
700117-01
Combination instrument - tachometer

5.12
The tachometer  shows the engine speed in revolutions per minute.

The red marking  shows the excess speed range of the engine.
100118-10
CONTROLS 25
Combination instrument - indicator lamps

5.13
The indicator lamps offer additional information about the operating state of the motorcy-
cle.
Possible states
The flasher indicator lamp flashes green simultaneously with the flashers
– Flasher light is switched on.
The idle speed indicator lamp lights up green – The transmission is

switched to idle.
High beam indicator lamp lights up blue – High beam is switched on.
100119-10
Temperature warning lamp lights up red – Coolant has reached a critical

value.
Fuel level warning lamp lights up orange – Fuel level has reached the
reserve mark. Display switched to TRIP F.
FI warning lamp (MIL) lights up/flashes orange – The OBD has detected an
emission- or safety-critical fault.
Battery warning lamp lights up red – Voltage in vehicle system too low.
CONTROLS 26
Combination instrument - display

5.14
When you switch on the ignition, all display segments light up for a second as a function
test.
700118-01
LEnGTth
Following the display function test, the wheel circumference LEnGth is shown for one sec-
ond.
Info
1870 mm corresponds to the circumference of the 17" front wheel with a series pro-
duction tire.
The display then changes to the last selected mode.

700119-01
CONTROLS 27
Combination instrument - speedometer

5.15
The speed  is shown in kilometers per hour km/h or in miles per hour Mph.
700114-01
Setting kilometers or miles

5.16
Info
If you change the unit, the value ODO is retained and converted accordingly.
Making the setting according to the country.
Condition
The motorcycle is standing.
CONTROLS 28
– Switch on the ignition by turning the ignition key to the position .

– Press the MODE button repeatedly until the ODO mode is active.
– Keep the MODE button pressed until the display mode changes from Km/h to Mph or
from Mph to Km/h.
Guideline
Activation duration of MODE button 10 s
700120-01
Combination instrument - time

5.17
The time is shown in area  of the display.
Info
The time has to be reset after the battery is reconnected or when the fuse is
changed.
700115-01
Setting the clock

5.18
Condition
The motorcycle is standing.
CONTROLS 29

– Press the MODE button repeatedly until the ODO mode is active.
– Keep the MODE button and the SET button pressed simultaneously.
The time display begins to flash.
– Press the MODE button to set the hour.
– Press the SET button to set the minute.
– Keep the MODE button and the SET button pressed simultaneously.
700115-10
The time is set.
Combination instrument - display ODO

5.19
In the ODO display mode, the total distance traveled is shown in kilometers or miles.
Info
This value is retained, even if the battery is disconnected and/or the fuse blows.
700120-01
Combination instrument - setting/resetting TRIP 1

5.20
Info
The TRIP 1 trip counter is always running and counts up to 999.9.
The trip counter can be used to measure the distance covered during trips or between two refueling stops. After the value 999.9 is
reached, the trip counter starts at 0.0 again.
CONTROLS 30

– Press the MODE button repeatedly until the TRIP 1 mode is active.
– Keep the SET button pressed.
The TRIP 1 display is set to 0.0.
700121-01
Combination instrument - setting/resetting TRIP 2

5.21
Info
The TRIP 2 trip counter is always running and counts up to 999.9.
The trip counter can be used to measure the distance covered during trips or between two refueling stops. After the value 999.9 is
reached, the trip counter starts at 0.0 again.

– Press the MODE button repeatedly until the TRIP 2 mode is active.
– Keep the SET button pressed.
The TRIP 2 display is set to 0.0.
700122-01
CONTROLS 31
Combination instrument - TRIP F display

5.22
If the fuel level drops to the reserve mark, the display automatically changes to TRIP F and
starts to count from 0.0, regardless of the previous display mode.
Info
Parallel to the TRIP F display, the fuel warning light switches on.
700123-01
Combination instrument - coolant temperature indicator

5.23
The temperature display consists of 12 bars. The more bars showing, the hotter the coolant.
When the top bar lights up, all bars begin to flash and the temperature warning light starts
to show.
Possible states
• Engine cold – Up to four bars light up.
• Engine at operating temperature – Five to eleven bars light up.
• Engine hot – All twelve bars flash.
700124-01
CONTROLS 32
Opening filler cap

5.24
– Lift the cover of the filler cap  and insert the ignition key.
– Turn the ignition key 90° counterclockwise and remove the filler cap.
Info
The filler cap has a tank air vent system.
500023-10
Closing filler cap

5.25
– Put the filler cap back on and turn the ignition key 90° clockwise.
– Remove the ignition key and fold down the cover.
500023-01
CONTROLS 33
Fuel taps
5.26
The fuel taps  are located on the left/right under the fuel tank.
Possible states
• Fuel supply closed – The knurled screws are turned clockwise as far as possible. The
level cannot be compensated and no fuel can flow out of the fuel tank.
• Fuel tap open – The knurled screws are turned counterclockwise as far as possible.
The level can be compensated and the fuel can flow out of the fuel tank.
700127-01
Handrails
5.27
The handrails  are used for moving the motorcycle around.

When you have a passenger, the passenger can hold on the handrails during the journey.
700130-01
CONTROLS 34
Seat lock
5.28
The seat lock  is located to the right of the seat.

You can lock it with the ignition key.
700131-01
Owner's manual
5.29
You can find the owner's manual  in its protective case on the underside of the seat.
500031-10
CONTROLS 35
Tool set
5.30
The tool set  is located in the storage compartment under the seat.
700134-01
Passenger footrests
5.31
The passenger footrests can be folded up and down.

Possible states
• Passenger footrests folded up – For operation without a passenger.
• Passenger footrests folded down – For operation with a passenger.
700135-01
CONTROLS 36
Shift lever
5.32
The shift lever  is mounted on the left side of the engine.
700137-01
The gear positions can be seen in the photograph.

The neutral or idle position is between the first and second gears.
700138-01
CONTROLS 37
Foot brake pedal

5.33
The footbrake pedal  is located in front of the right footrest.

The footbrake pedal operates the rear brake.
700136-01
Side stand
5.34
The side stand  is coupled with the safety electric starter system - see the riding instruc-
tions.
Possible states
• Side stand folded out – The vehicle can be supported on the side stand. The safety
electric starter system is active.
• Side stand folded in – This position is mandatory for all journeys. The safety electric
starter system is inactive.
700139-01
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 38
Advice on first use

6.1
Danger
Danger of accidents Danger from insufficient traffic competence.
– Do not use the vehicle if you are not fit to deal with traffic or if you have consumed alcohol and/or medicaments or drugs.
Warning
Risk of injury Missing or insufficient protective clothing increases the risk of injury.
– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear
protective clothing, which must be in perfect condition and meet legal requirements.
Warning
Danger of crashing Impairment of riding behavior due to different tire tread patterns on front and rear wheels.
– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidents Uncontrollable handling characteristics due to non-approved and/or non-recommended tires/wheels.
– Only tires/wheels approved by KTM and with the corresponding speed index should be used.
Warning
Danger of accidents Reduced road grip with new tires.
– New tires have a smooth roll surface and therefore cannot provide full road grip. The entire roll surface must be roughened in
the first 200 kilometers (124.3 miles) by moderate driving at alternating angles. The full grip is not reached until the vehicle
has been run in.
Warning
Danger of accidents Brake system failure.
– If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take your
foot off the foot brake pedal if you do not want to brake.
Info
When using your vehicle, remember that others may feel disturbed by excessive noise.
– Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.
You receive a delivery certificate and the service record at vehicle handover.
– Before your first trip, read the entire operating instructions carefully.
– Get to know the controls.
– Adjust the basic position of clutch lever. ( p. 122)
– Adjust the basic position of handbrake lever. ( p. 71)
– Adjust the basic position of the footbrake lever.
– Get used to handling the vehicle on a car park before making a longer trip. Try also to ride as slowly as possible and in a standing posi-
tion to get a better feeling for the vehicle.
– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
– Run the engine in.
Running in the engine

6.2
– During the running-in phase, do not exceed the specified engine speed and engine performance.
Guideline
Maximum engine speed
During the first: 1,000 km (621.4 mi) 6,000 rpm
After the first: 1,000 km (621.4 mi) 7,800 rpm
– Avoid fully opening the throttle!
Loading the vehicle

6.3
Warning
Danger of accidents Unstable riding behavior.
– Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a
full tank, driver and passenger with protective clothing and helmet, baggage.
Warning
Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack.
– Mount and secure suitcase and tank rucksack according to the manufacturer's instructions.
Warning
Danger of accidents Unstable handling characteristics at high speed.
– Adapt your speed according to your payload. Ride more slowly if your motorcycle is loaded with cases or other baggage.
Maximum speed with baggage 130 km/h (80.8 mph)
Warning
Danger of accidents Risk of breakage of suitcase system.
– If you have fitted suitcases on your motorcycle, read the manufacturer's specifications concerning the maximum payload.
Warning
Danger of accidents Poor visibility for other road users due to slipped baggage.
– If the tail light is covered, you are less visible to traffic behind you, especially in the dark. Check that your baggage is fixed
properly at regular intervals.
Warning
Danger of accidents Changed handling characteristics and longer stopping distance with excessive payload.
– Adapt your speed according to your payload.
Warning
Danger of accidents Unstable handling characteristics due to slipped baggage.
– Check the way your baggage is fixed regularly.
Warning
Danger of burns A hot exhaust system can burn baggage.
– Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system.
– If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu-
tion between the front and rear wheels.
– Do not exceed the overall maximum permitted weight and the axle loads.
Guideline
Maximum permissible overall weight 350 kg (772 lb.)
Maximum permissible front axle load 150 kg (331 lb.)
Maximum permissible rear axle load 200 kg (441 lb.)
RIDING INSTRUCTIONS 42
Checks before putting into operation

7.1
Info
Make sure that the motorcycle is in a perfect technical condition before use.
In the interests of riding safety, make a habit of making a general check before you ride.
– Check the engine oil level. ( p. 125)

– Check the engine for loss of oil.
– Check the fuel level.
– Bleed the fork legs. ( p. 63)
Guideline
All 1,000 km (621.4 mi)
– Check the chain tension. ( p. 65)
– Clean the chain. ( p. 64)
– Check the tire condition. ( p. 84)
– Check the tire air pressure. ( p. 85)
– Check the front brake fluid level. ( p. 71)
– Check the rear brake fluid level. ( p. 75)
– Check the front brake linings. ( p. 73)
– Check the rear brake linings. ( p. 77)
– Check brake system function.
– Check the coolant level. ( p. 118)
– Check that all operating elements are correctly adjusted and free to move.
– Check the functioning of the electrical equipment.
– Check that baggage is correctly secured.
– Sit on the motorcycle and check the rear mirror setting.
Starting
7.2
Danger
Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space
without an effective exhaust extraction system.
Caution
Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
– Never operate the vehicle with a discharged battery or without a battery.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
– Always warm up the engine at low engine speeds.
– Turn the emergency OFF switch to the position .

After you switch on the ignition, you can hear the fuel pump working for about 2
seconds. At the same time, the function test of the combination instrument is run.
– Shift gear to neutral.
The green idling speed indicator lamp N  lights up.
– Press the electric starter button .
Info
Do not press the electric starter button until the function test of the combination
instrument is finished.
When starting, DO NOT open the throttle. If you open the throttle during the start-
ing procedure, fuel is not injected by the engine management system and the
engine cannot start.
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before
trying again.
This motorcycle is equipped with a safety start system. You can only start the
engine if the gearbox is in neutral or if the clutch is pulled when a gear is
engaged. If the sidestand is folded out and you shift into gear and release the
clutch, the engine stops.
– Take the weight off the side stand and swing it back up with your foot as far as it will
go.
700140-01
Starting up
7.3
– Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.
Shifting, riding
7.4
Warning
Danger of accidents An abrupt load alterations can cause the vehicle to get out of control.
– Avoid abrupt load alterations and sudden braking actions, and adapt your speed to the road conditions.
Warning
Danger of accidents If you change down at high engine speed, the rear wheel can lock up.
– Do not change into a low gear at high engine speed. The engine races and the rear wheel can block.
Warning
Danger of accidents Malfunctions caused by incorrect ignition key position.
– Do not change the ignition key position during a journey.
Warning
Danger of accidents Distraction from traffic activity by adjustments to the vehicle.
– Make all adjustments when the vehicle is at a standstill.
Warning
Risk of injury The passenger must be capable of sitting correctly on the passenger seat.
– The passenger must hold on to the rider or the handrails and place his feet on the passenger footrests. Note the regulations
governing the minimum age of passengers in your country.
Warning
Danger of accidents Danger of accidents caused by dangerous driving.
– Observe the traffic regulations and ride defensively and with foresight in order to recognize danger as early as possible.
Warning
Danger of accidents Reduced road grip with cold tires.
– On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road
grip is ensured.
Warning
has been run in.
Warning
Danger of accidents Unstable riding behavior.
– Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a
full tank, driver and passenger with protective clothing and helmet, baggage.
Warning
Danger of accidents Unstable handling characteristics due to slipped baggage.
– Check the way your baggage is fixed regularly.
Warning
Danger of accidents After a fall, check the vehicle.
– After a fall, check the vehicle as usual before putting it into operation.
Note
Engine failure Unfiltered intake air has a negative effect on the service life of the engine.
– Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.
Note
Engine failure Overheating of engine.
– If the coolant temperature warning lamp lights up, stop and switch off the engine. Allow the engine to cool down and check the
coolant level in the radiator, and top up if necessary. If you continue with the coolant temperature warning lamp alight, you may have
engine failure.
Info
If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.
– When conditions allow (incline, road situation, etc.), you can shift into a higher gear.
– Release the throttle while simultaneously pulling the clutch lever, shift into the next
gear, release the clutch and open the throttle.
Info
You can see the positions of the 6 forward gears in the figure. The neutral or idle
position is between the first and second gears. First gear is used for starting off
or for steep inclines.
The operating temperature is reached when 5 bars of the temperature indicator
700138-01 light up.
– 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 consid-
erably lower.
– Accelerate only up to a speed suitable for the road surface and weather conditions. Par-
ticularly in bends, do not shift, and accelerate very carefully.
– To shift down, brake if necessary and close the throttle at the same time.
– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open
the throttle or shift again.
– If the engine stalls (e.g. at a crossroads), just pull the clutch lever and press the starter
button. You do not need to shift into neutral.
– Switch off the engine if you expect to be standing for a long time.
– If the FI warning lamp (MIL) lights up during a journey, stop immediately. When you
shift to neutral, the FI warning lamp (MIL) starts to flash.
Info
From the flashing rhythm, you can derive a two-digit number, the so-called
flashing code. The flashing code tells you which component has a fault.
Braking
7.5
Warning
Danger of accidents If you brake too hard, the wheels can lock.
– Adapt your braking to the traffic situation and the road conditions.
Warning
Danger of accidents Reduced braking due to wet or dirty brakes.
– Clean or dry dirty or wet brakes by riding and braking gently.
Warning
Danger of accidents Reduced braking caused by spongy pressure point of front or rear brake.
– Have the brake system checked in an authorized KTM workshop, and do not ride any further.
Warning
– If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take your
foot off the foot brake pedal if you do not want to brake.
Warning
Danger of accidents Longer stopping distance due to higher overall weight.
– Take the longer stopping distance into account when carrying a passenger and baggage.
Warning
Danger of accidents Delayed brake action on salted roads.
– Salt can be deposited on the brake discs. To achieve the normal braking effect, the brake discs must first be cleaned by brak-
ing.
– To brake, release the throttle and operate the front and rear brakes simultaneously.
– On sandy, wet or slippery surfaces, use the rear brake.
– Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
– On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine. In
this way, you have to brake far less and the brakes do not overheat.
Stopping, parking
7.6
Warning
Risk of misappropriation Usage by unauthorized persons.
– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. If you leave the
vehicle, lock the steering and remove the ignition key.
Warning
Danger of burns Some vehicle components get very hot when the machine is driven.
– Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these components to
cool down before starting work on them.
Note

Note
Fire hazard Some vehicle components get very hot when the machine is driven.
– Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is still warm
from being run. Always let the vehicle cool first.
Note
Material damage Damage and destruction of components by excessive load.
– The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand
only. The side stand and/or the frame could be damaged and the motorcycle could fall over.
– Brake the motorcycle.

– Switch off the ignition by turning the ignition key to the position .
Info
If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock, power
continues to flow to most power consumers and the battery will discharge. You should therefore always switch off the engine
with the ignition key - the emergency OFF switch is intended for emergencies only.
– Park the motorcycle on a hard surface.

– Swing the side stand forward with your foot as far as it will go and lean the vehicle on it.
– Lock the steering by turning the handlebar fully to the left, pressing down the ignition key to position and turning it to position .
To make the steering lock engage more easily, move the handlebar a little to the left and right. Remove the ignition key.
Refueling
7.7
Danger
Fire hazard Fuel can easily catch fire.
– Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is
spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately
with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doc-
tor immediately. Change clothing that has come into contact with fuel.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
Info
This motorcycle is equipped with a regulated catalyst. Leaded fuel will destroy the catalyst. You should therefore use unleaded fuel
only.
– Switch off the engine.

– Open the filler cap. ( p. 32)
– Fill the fuel tank with fuel up to measurement .
Guideline
Level  50 mm (1.97 in)
Total fuel tank 13.5 l Super unleaded (ROZ 95 / RON 95 /

capacity, approx. (3.57 US gal) PON 91) ( p. 165)
100120-10 – Close the filler cap. ( p. 32)
– Press the SET button  for two seconds.
The fuel level warning lamp  switches off. TRIP F is set to 0 and appears in the
previous display mode.
Info
If you do not press the SET  button, the reset takes place automatically after
about 3 minutes.
100121-10
SERVICE SCHEDULE 53
Important maintenance work to be carried out by an authorized KTM workshop.

8.1
K10N K50A K100A J1A J2A

Engine Change the engine oil and filter, clean the oil screens. x( p. 126) • • • • •
Check and adjust valve clearance. x • •
Check engine mounting screws for tightness. • • • • •
Replace spark plug. •
Check engine bolts accessible from outside for tightness. • • • • •
Fuel injection Check connection boots for cracks and leakage. x • • •
Read out the error memory with a KTM diagnostic tool. x • • • • •
Check fuel hoses, SLS hoses and vent hoses for damage, correct fit-
• • • • •
ting and leaks. x
Clean, check and grease the O-ring of the fuel hose connection. x • • • •
Check the cable harness of the throttle valve body for damage and cor-
• • •
rect positioning.x
Attachments Check the cooling system for leakage. • • • • •
Check the antifreeze and coolant level. ( p. 115) • • • • •
Check the functioning of the radiator fan. x • • • • •
Check the exhaust system for leaks and correct fitting and check that
• • • • •
the exhaust holders are tight. x
Check Bowden cables for damage, smooth operation, routing without
• • • • •
sharp bends and setting.
Check/rectify the fluid level of the hydraulic clutch. ( p. 123) • • • •
Check air filter and change if necessary. Clean the air filter box. x • • • •
Check fuel tank for tightness. • • • • •
Check cables for damage and routing without sharp bends. x • • • • •
SERVICE SCHEDULE 54

Attachments Check the headlamp setting. • • • • •
Check the functioning of the electrical equipment. • • • • •
Check screws and nuts for tightness. • • • • •
Brakes Check the front brake linings. ( p. 73) • • • • •
Check the rear brake linings. ( p. 77) • • • • •
Check the brake discs. ( p. 70) • • • • •
Check the front brake fluid level. ( p. 71) • • • • •
Check the rear brake fluid level. ( p. 75) • • • • •
Change brake fluid. x •
Check brake lines for damage and leakage. • • • • •
Check the free play of the foot brake lever. ( p. 74) • • • • •
Check braking. • • • • •
Check screws and guide bolts of brake system for tightness.x • • • • •
Chassis Check shock absorber and fork for leakage and functioning. x • • • • •
Clean the dust boots of the fork legs. • • • •
Bleed the fork legs. ( p. 63) • • • • •
Check swingarm bearing. x • • • • •
Check the steering head bearing play. x • • • • •
Check all screws to see if they are tight. • • • • •
Grease Pro‑Lever deflector. x •
Wheels Check rim run-out. x • • • • •
Check the tire condition. ( p. 84) • • • • •
Check the tire air pressure. ( p. 85) • • • • •
SERVICE SCHEDULE 55

Wheels Check the chain wear. ( p. 69) • • • • •
Check rear sprocket / engine sprocket for tightness. • • • • •
Check rear sprocket / engine sprocket for wear. ( p. 68) • • • • •
Check the chain tension. ( p. 65) • • • • •
Clean the chain. ( p. 64) • • • • •
Check wheel bearing for play. x • • • •
Check the rear hub rubber dampers. x( p. 83) • • • •
K10N: after 1,000 km (621.4 mi)
K50A: every 5,000 km (3,107 mi) / after every race
K100A: every 10,000 km (6,214 mi)
J1A: annually
J2A: every 2 years
Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)
8.2
K100A J1A J2A

Carry out a complete fork service. x • •
Carry out a complete shock absorber service. x • •
Clean and grease steering head bearing and sealing elements. x •
Treat electric contacts with contact spray. • •
Clean the battery terminals and treat them with contact grease. • •
Change coolant. x •
K100A: every 10,000 km (6,214 mi)
J1A: annually
J2A: every 2 years
MAINTENANCE WORK ON CHASSIS AND ENGINE 56
Jacking up front of motorcycle

9.1
Note
– Jack up the rear of the motorcycle. ( p. 57)

– Move the handlebar to the straight-ahead position. Align the work stand to the front
with the adapters to the fork legs.
Work stand front (61029055300)
Info
Always jack up the rear of the motorcycle first.
– Jack up the front of the motorcycle.
700141-01
Taking front from work stand

9.2
Note
– Secure the motorcycle against falling over.

– Remove the work stand at the front.
Jacking up rear of motorcycle

9.3
Note
– Insert the work stand adapter in the work stand and screw it into the link forks.
Work stand adapter (61029055110)
Work stand rear (61029055100)
– Stand the motorcycle upright, align the work stand to the rear, and jack up the motorcy-
cle.
700142-01
Taking the rear from the workstand

9.4
Note
– Secure the motorcycle against falling over.

– Remove the work stand from the rear and lean the vehicle on the side stand.
Fork/shock absorber
9.5
The fork and the shock absorber offer many options of adapting the chassis to your riding
style and the payload.
Info
To help you adapt the vehicle, we have summarized our findings in Table . You
can find the table on the air filter box under the seat.
These adjustments should be understood as a guideline and should always be the basis
of your own personal chassis adaptation. Do not change the adjustments at random or by
700143-01
more than ± 40%, since otherwise the riding characteristics could deteriorate, particularly
at high speeds.
Adjusting the compression damping of the fork

9.6
Info
The hydraulic compression damping determines the fork suspension behavior.
– Turn adjusting screws  clockwise until they stop.
Info
The adjusting screws are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
700146-01
– Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Full payload 10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce suspension
damping.
Adjusting the rebound damping of the fork

9.7
Info
The hydraulic rebound damping determines the fork rebound behavior.
– Turn adjusting screws  clockwise until they stop.
Info
The adjusting screws are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
700145-01
– Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce suspension
damping.
Compression damping of the shock absorber

9.8
The shock absorber can regulate compression damping in low- and high-speed range separately (Dual Compression Control).
The term low speed and high speed refer to the movement of the shock absorber during compression and not the riding speed of the
motorcycle.
Changes in the settings in the low-speed range have an impact on the high-speed range and vice versa.
Adjusting the low-speed compression damping of the shock absorber

9.9
Danger
Danger of accidents The shock absorber is under high pressure.
– The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any mainte-
nance on it yourself.
Info
The low-speed setting can be seen during the slow to normal compression of the shock absorber.
– Turn adjusting screw  clockwise with a screwdriver as far as the last perceptible click.
Info
Do not loosen nut !
– Turn back counterclockwise by the number of clicks corresponding to the shock

absorber type.
Guideline
Compression damping, low-speed
700144-01
Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Info
damping.
Adjusting the high-speed compression damping of the shock absorber

9.10
Danger
Info
The high-speed setting can be seen during the fast compression of the shock absorber.
– Turn adjusting screw  clockwise as far as it will go using an open end wrench.
Info
Do not loosen nut !
– Turn back counterclockwise by the number of turns corresponding to the shock

absorber type.
Guideline
Compression damping, high-speed
700147-01
Comfort 2.5 turns
Standard 2.0 turns
Sport 1.5 turns
Full payload 1.5 turns
Info
damping.
Adjusting the rebound damping of the shock absorber

9.11
Danger
– Turn adjusting screw  clockwise to the last perceptible click.

– Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
700148-01
Info
Turn clockwise to increase damping; turn counterclockwise to reduce suspension
damping.
Bleeding the fork legs

9.12
– Lean the motorcycle on the side stand.

– Remove bleeder screws  briefly.
Any excess pressure escapes from the interior of the fork.
– Mount and tighten bleeder screws.
Info
Carry out this action on both fork legs.
600830-10
Checking chain dirt

9.13
– Check the chain for coarse dirt accumulation.

» If the chain is very dirty:
Cleaning the chain

9.14
Warning
Danger of accidents Oil or grease on the tires reduces their grip.
– Remove oil and grease with a suitable cleaning material.
Warning
Danger of accidents Reduced braking due to oil or grease on the brake discs.
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Environmental hazard Problem materials cause environmental damage.
– Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc., according to regulations.
Info
The service life of the chain depends largely on its maintenance.
– Clean the chain regularly.

– Rinse off loose dirt with a soft jet of water.
– Remove old grease remains with chain cleaner.
Chain cleaner ( p. 166)
– After drying, apply chain spray.

Onroad chain spray ( p. 167)
Checking the chain tension

9.15
Warning
Danger of accidents Danger caused by incorrect chain tension.
– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings
in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture
or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or
the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary.
– Lean the motorcycle on the side stand.

– Push the chain upwards near the vertical rib of the swingarm and measure the chain
tension .
Info
The upper chain section  must be taut.
Chain wear is not always even, so you should repeat this measurement at differ-
ent chain positions.
Chain tension 5 mm (0.2 in)

» If the chain tension does not meet specifications:
– Adjust the chain tension. ( p. 66)
700150-01
Adjusting the chain tension

9.16
Warning
Danger of accidents Danger caused by incorrect chain tension.
– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings
in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture
or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or
the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary.
– Check the chain tension. ( p. 65)

– Loosen nut .
– Loosen nuts .
– Adjust the chain tension by turning adjusting screws  on the left and right.
Guideline
Chain tension 5 mm (0.2 in)
Turn the left and right adjusting screws  so that the markings on the left and right
chain adjusters  are in the same position relative to the reference marks . The
rear wheel is then correctly aligned.
Info
The upper chain section must be taut.
Chain wear is not always even, so you should check this setting at different
chain positions.
– Tighten nuts .
– Make sure that the chain adjusters  are installed correctly on adjusting screws .
– Tighten nut .
Guideline
100131-10 Nut, rear wheel spindle M25x1.5 90 Nm
(66.4 lbf ft)
Info
The wide adjustment range of the chain adjusters (30 mm (1.18 in)) enables
different secondary transmissions with the same chain length.
The chain adjusters  can be turned through 180°.
Checking rear sprocket / engine sprocket for wear

9.17
– Check rear sprocket / engine sprocket for wear.

» If the rear sprocket / engine sprocket are worn:
– Replace rear sprocket / engine sprocket.
Info
The engine sprocket, rear sprocket and chain should always be replaced
together.
For safety reasons, the chain has no chain joint. Always have the chain
replaced in an authorized KTM workshop, where the necessary chain
100132-10 rivet tool is available.
– Check chain guides for tightness and wear.

Checking chain wear

9.18
– Shift into neutral, and pull the lower chain section with the specified weight .
Guideline
Weight of chain wear measurement 15 kg (33 lb.)
– Measure distance  of 18 chain segments of the lower chain section.
Info
Chain wear is not always even, so you should repeat this measurement at differ-
ent chain positions.
Maximum distance  at the longest sec- 272 mm (10.71 in)

tion of the chain
» If distance  is greater than the specified measurement:
– Have the chain changed.
Info
When the chain is replaced, the rear sprocket and engine sprocket
should be replaced at the same time.
A new chain will wear faster on an old, worn rear sprocket or engine
sprocket.
700152-01 For safety reasons, the chain has no chain joint. Always have the chain
changed in an authorized KTM workshop, where they have the necessary
special tools.
Checking brake discs

9.19
Warning
Danger of accidents Reduced braking due to worn brake discs.
– Worn brake discs should be replaced immediately in an authorized KTM workshop.
– Check the thickness of the front and rear brake discs in several places to ensure that it
conforms to measurement .
Info
Wear reduces the thickness of the brake disc in the area  of the brake disc.
Brake discs - wear limit

Front 3.6 mm (0.142 in)
Rear 4.5 mm (0.177 in)
100135-10
» If the brake disc thickness is less than the specified value:
– Replace the brake disc.
– Check the front and rear brake discs for damage, cracks, and deformation.
» If damage, cracks, or deformation are visible on the brake disc:
– Replace the brake disc.
Adjusting basic position of handbrake lever

9.20
– Adjust the basic setting of the handbrake lever to your hand size by turning adjusting
wheel .
Info
Pull the brake lever forwards and turn the adjusting wheel.
Do not make any adjustments while riding!
100117-10
Checking the front brake fluid level

9.21
Warning
– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have
the brake system checked in an authorized KTM workshop, and do not ride any further.
Warning
Danger of accidents Reduced braking due to old brake fluid.
– Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Check the brake fluid level in the viewer .
» If the brake fluid level is below the MIN mark:
– Add front brake fluid. x( p. 72)
100134-11
Adding front brake fluid

9.22 x
Warning
Warning
Skin irritations Brake fluid can cause skin irritation on contact.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Warning
Info
Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Loosen screw.
– Remove cover  with membrane .
– Add brake fluid to MAX mark.
Brake fluid DOT 4 / DOT 5.1 ( p. 162)
– Check parts for damage and wear. Replace damaged or worn parts.
– Position the cover with the membrane. Mount and tighten the screws.
Info
100181-10
Clean up overflowed or spilt brake fluid immediately with water.
Checking the front brake linings

9.23
Warning
Danger of accidents Reduced braking due to worn brake linings.
– Worn brake linings should be replaced immediately in an authorized KTM workshop.
Note
Danger of accidents Reduced braking due to damaged brake discs.
– If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly
reduced and the brake discs are destroyed.
– Check the brake linings for minimum thickness .

Minimum thickness  ≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the front brake linings. x
– Check the brake linings for damage and cracking.
» If there is wear or tearing:
– Change the front brake linings. x
100137-10
Checking free play of foot brake lever

9.24
Warning
– If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can
fail due to overheating. Adjust free travel on foot brake pedal according to specifications.
– Disconnect spring .
– Move the foot brake lever backwards and forwards between the end stop and the foot
brake cylinder piston bracket and check free play .
Guideline
Free play at foot brake lever 3… 5 mm (0.12… 0.2 in)
» If the free travel does not meet specifications:
– Have the free travel corrected in an authorized KTM workshop.
– Reconnect spring .
700153-01
Checking rear brake fluid level

9.25
Warning
Warning
– Stand the vehicle upright.

– Check the brake fluid level in the brake fluid reservoir.
» If the fluid level reaches the MIN marking :
– Add rear brake fluid. x( p. 76)
700154-01
Adding rear brake fluid

9.26 x
Warning
Warning
Skin irritations Brake fluid can cause skin irritation on contact.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Warning
Info
Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
– Stand the vehicle upright.

– Remove the screw cap  with the membrane .
– Add brake fluid to MAX mark.
Brake fluid DOT 4 / DOT 5.1 ( p. 162)
– Mount the screw cap with the membrane.
Info
Clean up overflowed or spilt brake fluid immediately with water.
100176-10
Checking the rear brake linings

9.27
Warning
Danger of accidents Reduced braking due to worn brake linings.
– Worn brake linings should be replaced immediately in an authorized KTM workshop.
Note
– If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly
reduced and the brake discs are destroyed.
– Check the brake linings for minimum thickness .

Minimum thickness  ≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the rear brake linings. x
– Check the brake linings for damage and cracking.
» If there is wear or tearing:
– Change the rear brake linings. x
100139-10
Removing front wheel

9.28 x
– Jack up the front of the motorcycle. ( p. 56)
– Remove screw  and spacing sleeve .
– Press back the brake linings with a light lateral tilting of the brake caliper on the brake
disc. Pull the brake caliper carefully back from the brake disc and hang it to one side.
Info
Do not pull the handbrake lever when the brake caliper is removed.
700155-10
– Loosed screw  and screw .

– Screw out screw  about 6 turns, press your hand on the screw to push the wheel spin-
dle out of the fork stub. Remove screw .
Warning
– Always lay the wheel down in such a way that the brake disc is not damaged.
– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the
700156-10 fork.
Installing the front wheel

9.29 x
Warning
– Clean and grease the thread of the wheel spindle and screw .
Long-life grease ( p. 167)
– Lift the front wheel into the fork, position it, and insert the wheel spindle. Mount and
tighten screw .
Guideline
Screw, front wheel spindle M24x1.5 40 Nm
(29.5 lbf ft)
700155-11 – Position the brake caliper and check that the brake linings are seated correctly.
– Position the spacing sleeves . Mount screws .
– Operate the hand brake lever several times until the brake pads are lying correctly on
the brake disc.
Info
This will cause the brake caliper to align with the brake disc.
– Fully tighten screws .

Guideline
Screw, front brake caliper M10x1.25 45 Nm Loctite® 243™
(33.2 lbf ft)
– Take the front from the work stand. ( p. 56)
– Pull the front wheel brake and push down hard on the fork several times to align the
fork legs.
– Fully tighten screws .
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
– Taking rear from work stand. ( p. 57)
600826-10
Removing rear wheel

9.30 x
– Remove nut . Remove chain adjuster . Holding the rear wheel, withdraw the wheel
spindle .
– Push the rear wheel forwards as far as possible and take the chain off the rear sprocket.
100144-10
– Pull the rear wheel and brake caliper support  together to the rear until you can swing
the brake caliper support to the side.
Warning
– Always lay the wheel down in such a way that the brake disc is not damaged.
– Take the rear wheel out of the swing arm.
100145-10 Info
Do not operate the foot brake when the rear wheel is removed.
Installing the rear wheel

9.31 x
Warning
Warning
Danger of accidents No braking effect when operating the rear brake.
– After installing the rear wheel, always operate the footbrake until the pressure point is reached.
– Check the rear hub rubber dampers. x( p. 83)

– Remove the bushing . Clean and grease the working surfaces of the bushing and shaft
seal ring .
– Clean and grease the thread of the wheel spindle and nut .
– Clean the fixing locations on the brake caliper support and swingarm.
– Install the rubber damper and rear sprocket carrier in the rear wheel.
100146-10 – Stand the rear wheel in the swingarm and mount the brake caliper on the brake disc.
– Push the brake caliper support and the swingarm  into the fixing location. Lay the
chain on the rear sprocket and mount the wheel spindle.
Info
Mount the left and right chain adjusters  in the same position.
– Push the rear wheel forward so that the chain adjusters are in contact with the adjust-
ing screws, and tighten nut .
Guideline
100147-10 In order for the rear wheel to be correctly aligned, the markings on the left and right
chain adjusters must be in the same position relative to the reference marks .
Nut, rear wheel spindle M25x1.5 90 Nm

(66.4 lbf ft)
– Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and
there is a tight spot.
Checking the rear hub rubber dampers

9.32 x
Info
The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during
operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged.
– Remove the rear wheel. x( p. 80)

– Check the rubber dampers of the rear hub for damage and wear.
» If the rubber dampers of the rear hub are damaged or worn:
– Change all rubber dampers in the rear hub.
100148-10
– Lay the read wheel on a workbench with the rear sprocket facing upwards and insert the
wheel spindle in the hub.
– To check the play , hold the rear wheel tight and try to rotate the rear sprocket.
Info
Measure the play on the outside of the rear sprocket.
Play in rubber dampers, rear wheel ≤ 5 mm (≤ 0.2 in)

» If clearance  is larger than the specified value:
100149-10
– Change all rubber dampers in the rear hub.
– Install the rear wheel. x( p. 81)
Checking the tire condition

9.33
Warning
Danger of accidents Uncontrollable handling behavior caused by a flat tire.
– For your own safety, have damaged tires changed immediately.
Warning
Danger of crashing Impairment of riding behavior due to different tire tread patterns on front and rear wheels.
– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidents Uncontrollable handling characteristics due to non-approved and/or non-recommended tires/wheels.
– Only tires/wheels approved by KTM and with the corresponding speed index should be used.
Warning
has been run in.
Info
The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.
Worn tires have a negative effect on riding behavior, especially on wet surfaces.
– Check the front and rear tires for cuts, run-in objects and other damage.
» If the tires exhibit cuts, run-in objects or other damage:
– Change the tires.
– Check the depth of the tread.
Info
Note local national regulations concerning the minimum tread depth.
Minimum tread depth ≥ 2 mm (≥ 0.08 in)

400602-10
» If the tread depth is less than the minimum permissible depth:
– Change the tires.
Checking tire air pressure

9.34
Info
Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.
– Remove dust cap.

– Check tire air pressure when tires are cold.
Tire air pressure, Solo
Front 2.0 bar (29 psi)
Rear 2.0 bar (29 psi)
Tire air pressure with passenger / fully loaded
700158-01 Rear 2.2 bar (32 psi)
» If the tire pressure does not meet specifications:
– Correct tire pressure.
– Mount dust cap.
Removing the seat

9.35
– Insert the ignition key in the seat lock  and turn it 45° counterclockwise.
– Lift up the seat at the rear, pull it back and remove from above.
700131-01
Mounting the seat

9.36
– Suspend the seat on the screw , press the rear downwards and at the same time push
it forwards. The two projections  must be inserted into the frame.
– Push the locking pin  into the lock housing and push the back of the seat down until
the locking pin locks in place with an audible click.
– Remove the ignition key from the seat lock.
– Finally, check that the seat is correctly mounted.
700199-01
Reinstalling the fuel tank

9.37
– Remove the seat. ( p. 86)

– Remove screw .
Info
The fuel lines do not need to be disconnected.
700159-01
– Lay a cloth  over the subframe and straighten the steering.

– Carefully raise the fuel tank and move it backwards.
– Place the fuel tank on the vehicle so that the left spoiler is still lying on the compensat-
ing tank  (see illustration). Place a cloth  between the compensating tank and the
spoiler to prevent damage.
700160-10
Positioning the fuel tank

9.38
– Remove the cloth  from between the compensating tank and the spoiler.
700160-11
– Carefully move the fuel tank forwards and lower it.

– Mount and tighten screw  with bearing sleeve  and rubber bushing . Check fuel
tank for tight fitting.
Guideline
Screw, fuel tank bracket M8 15 Nm
(11.1 lbf ft)
– Check the routing of the fuel hoses.
– Mount the seat. ( p. 87)
700161-01
Removing the battery

9.39 x
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep the battery away from sparks or open fire. Charge only in well-ventilated rooms.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15
minutes and contact a physician.

– Reinstall the fuel tank. ( p. 87)
– Disconnect the negative (minus) cable  of the battery.

– Detach rubber band .
700162-10
– Fold up positive terminal cover .

– Disconnect the positive (plus) cable  of the battery.
– Detach rubber band .
700163-10
– Disconnect plug-in connector .

– Remove cover .
700164-10
– Pull battery  up and out of the battery rack. Take the battery out of the frame toward
the right.
Info
Never operate the motorcycle with a discharged battery or without a battery. In
both cases, electrical components and safety devices can be damaged. The vehi-
cle is therefore no longer roadworthy.
700165-10
Installing the battery

9.40 x
– Push battery  from the right into the frame. Position the battery in the battery rack.
Info
The battery terminals must be at the front.
700165-11
– Position cover .
– Connect plug-in connector .
700164-11
– Secure the cover with rubber band .

– Connect positive cable . Position positive terminal cover .
700163-11
– Secure the cover with rubber band .

– Attach the minus cable .
– Position the fuel tank. ( p. 88)
– Set the clock. ( p. 28)
700162-11
Recharging the battery

9.41 x
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep the battery away from sparks or open fire. Charge only in well-ventilated rooms.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15
minutes and contact a physician.
Warning
Environmental hazard Components and battery acid are a danger to the environment.
– Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.
Warning
Info
Even when there is no load on the battery, it still loses power steadily.
The charge state and the type of charge are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the battery's service life.
If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. This
reduces the battery capacity.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the battery.
The battery is maintenance-free, which means that the acid level does not need to be checked.
– Switch off all power consumers and switch off the engine.
– Disconnect the minus (negative) cable of the battery to avoid damage to the motorcy-
cle's electronics.
– Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test rest potential and start potential of the bat-
tery, and to test the generator. With this device, you cannot overcharge the battery.
Info
Never remove lid .
Charge the battery with a maximum of 10% of the capacity specified on the bat-
tery housing .
– Switch off the charger after charging. Disconnect the battery.

Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the 3 months
motorcycle is not in use
100151-10
Changing the main fuse

9.42
Warning
Fire hazard The electrical system can be overloaded by the use of incorrect fuses.
– Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
Info
The main fuse protects all power consumers in the vehicle. It is located in the starter relay housing next to the battery.
– Remove protective cover .
700166-01
– Use a needle nose plier to remove a defective main fuse .

– Check parts for damage and wear. Replace damaged or worn parts.
Info
A reserve fuse  is located in the starter relay.
– Insert the new main fuse.

Fuse (58011109130) ( p. 153)
700167-01
Info
If the new fuse burns out, contact an authorized KTM workshop.
– Replace protective cover .

Changing the fuses of power consumers

9.43
Info
The fuse box containing the fuses of the individual power consumers is located under the seat.
– Open fuse box cover .
700168-01
– Remove the defective fuse.

Guideline
Fuse 1 - 10A - ignition, combination instrument, alarm system (optional)
Fuse 2 - 10A - clock, ignition (EFI control unit)
Fuse 3 - 10A - throttle valve control unit
Fuse 4 - 10A - fuel pump
Fuse 5 - 10A - radiator fan
Fuse 6 - 10A - horn, brake light, flasher light, alarm system (optional)
Fuse 7 - 15A - high beam, low beam, parking light, tail light, license plate lamp
Fuse 8 - 10A - for accessories (in circuit with positive of ignition switch)
Fuse 9 - 10A - for accessories (permanent positive)
Fuse 10 - Not assigned
SPARE - 10A/15A - spare fuses
Info
You can recognize a defective fuse by the burned-out fuse wire .
100154-10
Warning
Fire hazard The electrical system can be overloaded by the use of incorrect
fuses.
– Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
– Replace with a spare fuse of the right rating.

Fuse (75011088010) ( p. 153)
Fuse (75011088015) ( p. 153)
Info
If the new fuse burns out, contact an authorized KTM workshop.
Tip
Put a new spare fuse in the fuse box for future use if needed.
– Checking the function of power consumers.

– Close the fuse box cover.
Adjusting the engine characteristic

9.44
– Switch off the ignition by turning the ignition key to the position .
– Pull the Map‑Select switch with holder  downward off of the retaining bracket.
700196-10
– Position the Map‑Select switch on the outside of the frame.

– Pull the Map‑Select switch out of the holder.
700197-01
– Turn the adjusting wheel until the desired digit is next to marking .
Info
Position 0 has no function.
Set the Map‑Select switch to Soft.

– Set the adjusting wheel to position 1.
Soft – reduced homologated peak performance for better driveability
700198-01
Set the Map‑Select switch to Advanced.

– Set the adjusting wheel to position 2.
Advanced – homologated performance with extremely direct responsiveness
Set the Map‑Select switch to Standard.
– Set the adjusting wheel to position 3, 4, 5, 6, 7, 8 or 9.
Standard – homologated performance with balanced responsiveness
– Position the Map‑Select switch in the holder.
– Push the Map‑Select switch with the holder upward onto the retaining bracket.
700196-11
Removing headlight mask with headlight

9.45
– Remove screws .
700169-10
– Swing the headlight mask forward.
700170-10
– Disconnect plug-in connector.
700171-01
– Remove the screw fitting  on both sides.

– Place the headlight mask to one side.
700172-10
Installing the headlight mask with the headlight

9.46
– Position the headlight mask. Mount and tighten screws  on both sides.
Guideline
Screw, headlight mask M6 5 Nm (3.7 lbf ft)
700172-11
– Connect the plug-in connector.
700171-01
– Fold the headlight mask up.
700170-11
– Position the headlight mask. Mount and tighten screws .

Guideline
– Check the lighting function.
700169-11
Changing the low beam bulb

9.47
Note
Damage to reflector Keep the glass of the bulb free of grease.
– Clean the glass bulb with a clean cloth before mounting. Any grease on the glass will evaporate due to the heat and be deposited on
the reflector.
700169-10
– Fold the headlight mask forward.
700170-10
– Turn headlight lamp  counterclockwise and remove it. Detach the connector.
– Position the new headlight bulb in the headlight housing. Connect the connector.
Low beam/high beam (HB3/P20d) ( p. 153)
Info
Insert the headlight bulb so that the bayonet lugs latch into the slots.
600828-10
700170-11
– Position the headlight mask. Mount and tighten screws .

Guideline
– Check lighting function.
700169-12
Change the high beam bulb

9.48
Note
the reflector.
700169-10
700170-10
– Turn headlight lamp  counterclockwise and remove it. Detach the connector.
– Position the new headlight bulb in the headlight housing. Connect the connector.
Low beam/high beam (HB3/P20d) ( p. 153)
Info
Insert the headlight bulb so that the bayonet lugs latch into the slots.
600829-10
700170-11
– Position the headlight mask. Mount and tighten screws .

Guideline
– Check lighting function.
700169-12
Changing the parking light bulb

9.49
Note
the reflector.
– Remove the headlight mask with the headlight. ( p. 100)

– Set down the headlight mask in front of you as shown in the illustration and carefully
tilt the high beam headlight in the direction of the low beam headlight.
– Turn the bulb holder  about 30° counterclockwise and remove it.
700175-01
– Pull the parking light bulb out of the holder.

– Insert a new parking light bulb in the holder.
Parking light (W2.1x9.5d) ( p. 153)
– Position the bulb holder and turn it clockwise as far as it will go.
– Install the headlight mask with the headlight. ( p. 102)
700176-01
Changing the flasher bulb

9.50
Note
the reflector.
– Remove the screw from the rear of the flasher housing.

– Tilt headlamp diffuser  forward carefully and take it off.
– Press the flasher bulb carefully into the socket, turn it counterclockwise by about 30°,
and take it out of the socket.
Info
Do not touch the reflector with your fingers, and keep it free from grease.
– Press the new flasher bulb carefully into the socket and turn it clockwise until it stops.
100160-10
Flasher light (BAU15s) ( p. 153)
– Position the diffuser.
– Insert the screw and turn it counterclockwise first until it engages in the thread. Tighten
the screw slightly.
– Check the flasher system function.
Checking the low beam headlight adjustment

9.51
– On a light-colored wall behind a horizontal area, make a mark as high as the center of
the low beam headlight.
A – Make another mark at a distance of  under the first mark.
Guideline
Distance  5 cm (2 in)
B – Stand the motorcycle at a distance of  in front of the wall and switch on the ignition.
Guideline
Distance  5 m (16 ft)
100159-10
– Check the low beam headlight adjustment.

The boundary between light and dark must be exactly on the lower mark for a motor-
cycle with driver.
» If the boundary between light and dark does not meet specifications:
– Adjust the light range of the low beam headlight. ( p. 112)
Checking the high beam headlight adjustment

9.52
– On a light-colored wall behind a horizontal area, make a mark as high as the center of
the high beam headlight.
A
0 – Make another mark at a distance of  under the first mark.
Guideline
Distance  5 cm (2 in)
0
B – Stand the motorcycle at a distance of  in front of the wall and switch on the high
beam.
Guideline
Distance  5 m (16 ft)
– Check the high beam headlight adjustment.
The center of the light cone must be exactly at the lower mark when the motorcycle is
operational and complete with a rider.
» If the center of the light cone is not located where specified:
B
0 – Adjust the light range of the high beam headlight. ( p. 113)
400575-10
Adjusting the light range of the low beam headlight

9.53

700169-10
– Adjust the beam distance of the headlight by turning screw .

Guideline
For a motorcycle with rider, the light/dark boundary must be exactly on the lower
mark (the mark is created in: Checking headlight adjustment).
Info
Turn clockwise to increase the headlight range; turn counterclockwise to reduce
the headlight range.
If you have a heavy payload, you will need to correct the headlight range.
700177-01

– Position the headlight mask. Mount and tighten screws .
Guideline
– Check the low beam headlight adjustment. ( p. 110)
700169-10
Adjusting the light range of the high beam headlight

9.54
– Adjust the light range of the high beam headlight. ( p. 113)

700169-10
– Adjust the beam distance of the headlight by turning screw .

Guideline
For a motorcycle with rider, the light/dark boundary must be exactly on the lower
mark (the mark is created in: Checking headlight adjustment).
Info
Turn clockwise to increase the beam width; turn counterclockwise to reduce the
beam width.
If you have a heavy payload, you will need to correct the headlight range.
700178-01

– Position the headlight mask. Mount and tighten screws .
Guideline
– Check the high beam headlight adjustment. ( p. 111)
– Adjust the light range of the high beam headlight. ( p. 113)
700169-10
Cooling system
9.55
The water pump  in the engine forces the coolant to flow.

The pressure resulting from the warming of the cooling system is regulated by a valve in
the radiator cap . Heat expansion causes excess coolant to flow into the compensating
tank . If the temperature falls, the excess coolant is sucked back into the cooling system.
The specified coolant temperature is therefore permissible without danger of function prob-
lems.
125 °C (257 °F)
700180-01
The coolant is cooled by the air stream and a radiator fan , which is controlled by a ther-
moswitch.
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling
effect.
100167-10
Checking antifreeze and coolant level

9.56
Warning
Scalding hazard During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other components of the cooling system when the engine is hot. Allow the engine
and radiator to cool down. If you are scalded, hold the affected part under cold water immediately.
Warning
Danger of poisoning Coolants are poisonous and a health hazard.
– Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately.
Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

Condition
Engine is cold.
– Stand the motorcycle upright on a horizontal surface.
– Remove the cap of the compensating tank .
– Check antifreeze of coolant.
−25… −45 °C (−13… −49 °F)
» If the antifreeze of the coolant does not meet specifications:
700181-10 – Correct the antifreeze of the coolant.
– Check the coolant level in the compensating tank.
The coolant level must be between MIN and MAX.
» If the coolant level does not meet specifications:
– Correct the coolant level.
Alternative 1
Coolant ( p. 162)
Alternative 2
Coolant (mixed ready to use) ( p. 162)
– Mount the cap of the compensating tank.
– Screw off the radiator cap .

– Check antifreeze of coolant.
−25… −45 °C (−13… −49 °F)
» If the antifreeze of the coolant does not meet specifications:
– Correct the antifreeze of the coolant.
– Check the coolant level in the radiator.
The radiator must be completely filled.
700182-11
– Rectify the coolant level and find out the cause of the loss.
Alternative 1
Coolant ( p. 162)
Alternative 2
» If you had to add more coolant than the specified amount:
> 0.50 l (> 0.53 qt.)
– Fill/bleed the cooling system. x( p. 120)
– Mount the radiator cap.
Checking the coolant level

9.57
Warning
Warning

Condition
Engine is cold.
– Check the coolant level in the compensating tank .
The coolant level must be between MIN and MAX.
– Correct the coolant level.
700181-10 Alternative 1
Coolant ( p. 162)
Alternative 2
– Screw off the radiator cap  and check the coolant level in the radiator.
The radiator must be completely filled.
– Rectify the coolant level and find out the cause of the loss.
Alternative 1
Coolant ( p. 162)
Alternative 2
700182-11
» If you had to add more coolant than the specified amount:
> 0.50 l (> 0.53 qt.)
– Mount the radiator cap.
Draining the coolant

9.58 x
Warning
Warning

– Stand the motorcycle upright.
– Place a suitable container under the engine.
– Remove screw . Remove the radiator cap.
– Completely drain the coolant.
– Mount screw  with a new seal ring and tighten it.
Guideline
Plug, drain hole of water pump M10x1 15 Nm
(11.1 lbf ft)
700184-01
Filling/bleeding the cooling system

9.59 x
Warning
Condition
Fuel tank is reset or removed.
– Remove radiator cap .
700182-10
– Remove bleeder screw .

– Tilt the vehicle slightly to the right.
– Pour in coolant until it emerges without bubbles at the vent hole, and then mount and
tighten the bleeder screw immediately.
Alternative 1
Coolant ( p. 162)
Alternative 2
700183-01
– Fill the radiator completely with coolant. Mount the radiator cap.
– Rest the vehicle on the sidestand.
Fuel tank is reset.
– Move the fuel tank forward.
The fuel tank is removed.
– Connect and position the fuel tank.
Danger
Danger of poisoning Exhaust gases are poisonous and can result in
unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation,
and do not start or run the engine in a closed space without an effective
exhaust extraction system.
– Start the engine and run it until the 5th bar of the temperature indicator lights up.
– Stop the engine and allow it to cool down.
– When the engine is cool, check the coolant level in the radiator and, if necessary, add
coolant.
– Remove the cap of the compensating tank  and add coolant until the coolant level is
up to the MAX mark.
– Mount the cap of the compensating tank.
700181-11
Adjusting basic position of clutch lever

9.60
Info
Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
– Adjust the basic setting of the clutch lever to your hand size by turning adjusting
screw .
100116-10
Checking/rectifying the fluid level of the hydraulic clutch

9.61
Info
The fluid level rises with increasing wear of the clutch lining disc.
Do not use brake fluid.
– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Check the fluid level.
The fuel level must be between MIN and MAX.
» If the level of the coolant does not meet specifications:
– Remove the screw cap with the membrane.
– Correct the fluid level of the hydraulic clutch.
Hydraulic fluid (15) ( p. 164)
– Mount the screw cap with the membrane.
100194-10
Checking play in gas Bowden cable

9.62
– Move the handlebar to the straight-ahead position. Move the throttle grip backwards
and forwards to ascertain the play in the gas Bowden cable.
Play in gas Bowden cable 3… 5 mm (0.12… 0.2 in)
» If the gas Bowden cable play does not meet specifications:
– Adjust the play in the gas Bowden cable. x( p. 125)
Danger
400192-10 unconsciousness and/or death.
– Start the engine and let it run idle. Move the handlebar to and fro over the entire steer-
ing range.
The idle speed must not change.
» If the idle speed changes:
– Adjust the play in the gas Bowden cable. x( p. 125)
Adjusting the play in the gas Bowden cable

9.63 x
– Move the handlebar to the straight-ahead position.
– Use the KTM diagnostics tool to set the throttle stepper motor to the neutral position.
– Loosen counter nut .
– Set the play in the gas Bowden cable by turning the adjusting screw .
Guideline
Play in gas Bowden cable 3… 5 mm (0.12… 0.2 in)
– Tighten counter nut .
100195-10
Checking engine oil level

9.64
Info
The engine oil level must be checked when the engine is at operating temperature.

Condition
The engine is at operating temperature.
– Check the engine oil level.
Info
After switching off the engine, wait for one minute and then check.
The engine oil must be between the lower and upper edge of the oil level viewer.
700185-01
» If the engine oil level is not at the specified level:
– Add the engine oil. ( p. 132)
Changing the engine oil and filter, cleaning the oil screens
9.65 x
– Drain the engine oil.
x ( p. 126)
– Remove the oil filter.
x ( p. 127)
– Clean the oil screens. x ( p. 129)
– Install the oil filter. x ( p. 129)
– Fill up with engine oil. x ( p. 131)
Draining the engine oil x

9.66
Warning
Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven.
– Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.
Warning
Info
Drain the engine oil only when the engine is warm.
– Stand the motorcycle on its side stand on a horizontal surface.


– Remove the oil drain plug  with the magnet and seal ring.
– Completely drain the engine oil.
700186-01
– Thoroughly clean the oil drain plug with a magnet.

– Mount the oil drain plug with the magnet and seal ring and tighten it.
Guideline
Oil drain plug with magnet M12x1.5 20 Nm
(14.8 lbf ft)
700187-01
Removing the oil filter

9.67 x
Warning
Warning

– Remove screws . Remove the oil filter cover  with the O-ring.
– Pull oil filter  out of the oil filter housing.
Circlip pliers reverse (51012011000)
700188-01
– Remove screws . Remove oil filter  with the O-ring.

– Pull oil filter  out of the oil filter housing.
Circlip pliers reverse (51012011000)
– Completely drain the engine oil.
– Thoroughly clean the parts and sealing area.
700189-01
Installing the oil filter

9.68 x
– Insert oil filters  and .
– Oil the O-rings of the oil filter cover. Mount oil filter covers  and .
– Mount and tighten the screws.
Guideline
Screw, oil filter cover M5 6 Nm (4.4 lbf ft)
700190-01
Cleaning the oil screens

9.69 x
Warning
Warning

– Remove plug  with oil screen  and the O-rings.
700191-01
– Remove plug  with oil screen  and the O-rings.

– Completely drain the remaining engine oil.
– Thoroughly clean the parts and sealing area.
700192-01
– Position oil screen  with the O-rings.

– Mount and tighten plug  with the O-ring.
Guideline
Plug, oil screen M20x1.5 15 Nm
(11.1 lbf ft)
700193-01
– Position oil screen  with the O-rings.

– Mount and tighten plug  with the O-ring.
Guideline
Plug, oil screen M20x1.5 15 Nm
(11.1 lbf ft)
700194-01
Filling up with engine oil

9.70 x
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
– Remove filler plug with O-ring  from the clutch cover and add engine oil.
Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60)
(00062010035) ( p. 163)
Alternative engine Engine oil
oil (SAE 10W/50)
( p. 163)
– Refit plug with O-ring  and tighten it.
700195-01 Danger
– Start the engine and check that it is oil-tight.

Adding engine oil

9.71
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
– Remove the oil filler plug with O-ring  from the clutch cover and fill up with engine
oil.
Engine oil (SAE 10W/60) (00062010035) ( p. 163)
Engine oil (SAE 10W/50) ( p. 163)
Info
For optimal performance of the engine oil, do not mix different types of engine
oil.
700195-01
If appropriate, change the engine oil.
– Install and tighten the oil filler plug with O-ring .
Danger
– Start the engine and check that it is oil-tight.

TROUBLESHOOTING 134
Faults Possible cause Action

The engine does not turn when the Operating error – Carry out the start procedure. ( p. 43)
starter button is pressed Battery discharged – Recharge the battery. x( p. 93)
– Check the cause of discharging.
Fuse 1, 2, 3, or 4 blown – Change the fuses of power consumers. ( p. 96)
Main fuse burned out – Change the main fuse. ( p. 95)
Ignition/steering lock or emergency – Have ignition/steering lock or emergency OFF
OFF switch defective switch checked.
Defect in safety start system – Have the safety start system checked.
No ground connection present. – Check the ground connection.
Engine turns only if the clutch lever is The vehicle is in gear – Shift gear to neutral.
drawn The vehicle is in gear and the side – Shift gear to neutral.
stand is folded out
Defect in safety start system – Have the safety start system checked.
Engine turns although a gear is Defect in safety start system – Have the safety start system checked.
engaged
Engine turns but does not start. Operating error – Carry out the start procedure. ( p. 43)
Fuse 4 blown – Change the fuses of power consumers. ( p. 96)
Coupling of fuel hose connection not – Reconnect coupling of fuel hose connection.
connected
Socket connector of cable harness oxi- – Clean socket connector and treat it with contact
dized spray.
Defect in fuel injection system – Read the error memory with the KTM diagnostics
tool and correct the fault.
Engine has too little power. Air filter very dirty – Have the air filter changed.
Fuel filter very dirty – Have the fuel filter changed.
TROUBLESHOOTING 135

Engine has too little power. Defect in fuel injection system – Read the error memory with the KTM diagnostics
Engine overheats. Too little coolant in cooling system – Check the cooling system for leakage.
– Check the coolant level. ( p. 118)
Radiator fins very dirty – Clean radiator fins.
Foam formation in cooling system – Drain the coolant. x( p. 119)
Buckled or damaged radiator hose – Have the radiator hose changed.
Thermostat defective – Have thermostat checked.
Fuse 5 blown – Change the fuses of power consumers. ( p. 96)
Defect in radiator fan system – Have the radiator fan system checked.
Air in cooling system – Fill/bleed the cooling system. x( p. 120)
FI warning lamp (MIL) lights/flashes Defect in fuel injection system – Read the error memory with the KTM diagnostics
Engine dies during the journey Lack of fuel – Refuel. ( p. 51)
Fuse 1, 2 or 4 blown – Change the fuses of power consumers. ( p. 96)
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. 125)
Engine oil too thin (low viscosity) – Change the engine oil and filter, clean the oil
screens. ( p. 126)
x
Headlight and parking light not func- Fuse 7 blown – Change the fuses of power consumers. ( p. 96)
tioning
Flasher light, brake light and horn not Fuse 6 blown – Change the fuses of power consumers. ( p. 96)
functioning
TROUBLESHOOTING 136

Time is not (correctly) displayed Fuse 2 blown – Change the fuses of power consumers. ( p. 96)
Battery discharged Ignition not switched off when vehicle – Recharge the battery. x( p. 93)
was parked
Battery is not charged by generator – Check charging voltage.
Combination instrument shows nothing Fuse 1 blown – Change the fuses of power consumers. ( p. 96)
in the display
Speedometer in combination instru- Speedometer cable harness damaged – Have the cable harness and plug checked.
ment not functioning or plug oxidized
FLASHING CODE 137
Flashing code FI of warning lamp 02 FI warning lamp (MIL) flashes briefly 2x

(MIL)
Possible cause Malfunction in ignition pulse generator circuit

(MIL)
Possible cause Input signal of throttle valve sensor circuit A too low
Input signal of throttle valve sensor circuit A too high

(MIL)
Possible cause Input signal from throttle grip sensor too low
Input signal from throttle grip sensor too high

(MIL)
Possible cause Input signal from pressure sensor, induction manifold (cylinder 1) too low
Input signal from pressure sensor, induction manifold (cylinder 1) too high
Flashing code FI of warning lamp 12 FI warning lamp (MIL) flashes 1x long, 2x short
(MIL)
Possible cause Input signal from coolant temperature sensor too low
Input signal from coolant temperature sensor too high
FLASHING CODE 138
(MIL)
Possible cause Input signal from intake air temperature sensor too low
Input signal from intake air temperature sensor too high
(MIL)
Possible cause Input signal of pressure sensor ambient air too low
Input signal of pressure sensor ambient air too high
(MIL)
Possible cause Input signal from rollover sensor too low
Input signal from rollover sensor too high
(MIL)
Possible cause Malfunction in lambda probe circuit (cylinder 1)
(MIL)
Possible cause Malfunction in circuit of EFI control unit or EPT control unit voltage supply
(MIL)
Possible cause Malfunction in sidestand switch circuit
FLASHING CODE 139
(MIL)
Possible cause Malfunction in circuit of Hall sensor throttle valve control
(MIL)
Possible cause Malfunction in the EPT control unit power supply circuit
(MIL)
Possible cause Malfunction in injection valve circuit (cylinder 1)
(MIL)
Possible cause Malfunction in ignition coil circuit (cylinder 1)
(MIL)
Possible cause Interruption/short-circuit to ground in fuel pump control circuit
(MIL)
Possible cause Malfunction or short circuit to ground in lambda probe heating circuit (cylinder 1)
FLASHING CODE 140
(MIL)
Possible cause Interruption/short-circuit to ground in secondary air valve circuit
(MIL)
Possible cause Malfunction of release of throttle stepper motor in EPT mode
Flashing code FI of warning lamp 60 FI warning lamp (MIL) flashes 6x long

(MIL)
Possible cause Malfunction in throttle stepper motor circuit
(MIL)
Possible cause The connection of the manifold absolute pressure sensor (cylinder 1) is not airtight
Flashing code FI of warning lamp 90 FI warning lamp (MIL) flashes 9x long

(MIL)
Possible cause Throttle value position not plausible
(MIL)
Possible cause Malfunction in CAN bus communication
FLASHING CODE 141
(MIL)
Possible cause Malfunction in voltage supply circuit of EPT control unit (internal)
CLEANING 142
Cleaning motorcycle
12.1
Note
Material damage Damage and destruction of components by high-pressure cleaning equipment.
– Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical
components, plug connectors, Bowden cables and bearings, etc., and can damage or destroy these parts.
Warning
Info
If you clean the motorcycle regularly, its value and appearance are maintained over a long period.
Avoid direct sunshine on the motorcycle during cleaning.
– Before you clean the motocycle, seal the exhaust system to prevent penetration by water.
– First remove coarse dirt particles with a gentle water spray.
– Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush.
Motorcycle cleaner ( p. 167)
Info
Use warm water containing normal motorcycle cleaner and a soft sponge.
If you have ridden the vehicle on salted roads, clean it with cold water. Warm water would reinforce the effect of the salt.
– After rinsing the motorcycle thoroughly with a soft jet of water, dry it with compressed air and a cloth.
CLEANING 143
Warning
Danger of accidents Reduced braking due to wet or dirty brakes.
– Clean or dry dirty or wet brakes by riding and braking gently.
– After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes.
Info
The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.
– Push back the protection covers on the handlebar instruments to allow water to evaporate.
– After the motorcycle has cooled off, oil or grease all moving parts and bearings.
– Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.
Cleaning and polishing materials for metal, rubber and plastic ( p. 166)
– Treat all painted parts with a mild paint polish.
High-luster polish for paint ( p. 166)
– To prevent electrical problems, treat electric contacts and switches with contact spray.
Contact spray ( p. 166)
– Oil the ignition/steering lock.
Universal oil spray ( p. 167)
PROTECTION FOR WINTER OPERATION 144
Conservation for winter operation

13.1
Info
If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive
road salt.
If you have ridden the vehicle on salted roads, clean it with cold water. Warm water would reinforce the effect of the salt.
– Clean the motorcycle. ( p. 142)

– Treat the engine, the swingarm, and all other bare or galvanized parts (except brake discs) with a wax-based anti-corrosion substance.
Info
To prevent serious reduction of the braking efficiency, make sure no anti-corrosion substance gets on to the brake discs.
After use on salted roads, clean the motorcycle thoroughly with cold water and dry it properly.

STORAGE 145
Storage
14.1
Info
If you want to garage the motorcycle for a longer period, take the following actions.
Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should
do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the
new season.
– Make sure the tank is as empty as possible so that you can fill up with fresh fuel when you put the motorcycle back into operation.
– Clean the motorcycle. ( p. 142)
– Change the engine oil and filter, clean the oil screens. x( p. 126)
– Check the antifreeze and coolant level. ( p. 115)
– Check the tire air pressure. ( p. 85)
– Remove the battery. x( p. 89)
– Recharge the battery. x( p. 93)
Guideline
Storage temperature of battery without direct sunshine. 0… 35 °C (32… 95 °F)
– The storage place should be dry and not subject to large temperature differences.
Info
KTM recommends jacking up the motorcycle.

– Jack up the front of the motorcycle. ( p. 56)
STORAGE 146
– Cover the motorcycle with a porous sheet or blanket.
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 exhaust system to rust.
Putting into operation after storage

14.2
– Take the front from the work stand. ( p. 56)

– Recharge the battery. x( p. 93)
– Install the battery. x( p. 91)
– Refuel. ( p. 51)
– Carry out checks before putting into operation. ( p. 42)
– Make a test ride.
TECHNICAL DATA - ENGINE 147
Design 1-cylinder 4-stroke engine, water-cooled

Displacement 654 cm³ (39.91 cu in)
Stroke 80 mm (3.15 in)
Bore 102 mm (4.02 in)
Compression ratio 11.8:1
Control OHC, 4 valves controlled via rocker arm, chain drive
Valve diameter, intake 40 mm (1.57 in)
Valve diameter, exhaust 34 mm (1.34 in)
Valve play, cold 0.07… 0.13 mm (0.0028… 0.0051 in)
Crankshaft bearing 2 roller bearings
Conrod bearing Needle bearing
Piston pin bearing Bronze bush
Pistons Forged light alloy
Piston rings 1 L-ring, 1 tapered compression piston ring, 1 oil scraper ring
Engine lubrication Semi-dry sump lubrication with two rotor pumps
Primary transmission 36:79
Clutch APTC™ Antihopping clutch in oil bath / hydraulically operated
Gearbox 6-gears, claw-shifted
Transmission ratio
1st gear 14:35
2nd gear 16:28
3rd gear 21:28
4th gear 21:23
5th gear 23:22
6th gear 23:20
TECHNICAL DATA - ENGINE 148
Mixture preparation Electronic fuel injection

Ignition Contactless controlled fully electronic ignition with digital ignition
adjustment
Generator 12 V, 224 W
Spark plug NGK LKAR 8AI - 9
Spark plug electrode gap 0.9 mm (0.035 in)
Cooling Water cooling, permanent circulation of coolant by water pump
Starting aid Electric starter, automatic decompressor
Capacity - engine oil

15.1
Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60) (00062010035) ( p. 163)
Alternative engine oil Engine oil (SAE 10W/50)
( p. 163)
Capacity - coolant
15.2
Coolant 1.20 l (1.27 qt.) Coolant ( p. 162)

TECHNICAL DATA - ENGINE TIGHTENING TORQUES 149
Oil hole plug self-tapping 9 Nm (6.6 lbf ft) Loctite® 243™

Screw, membrane fixation M3 2.5 Nm (1.84 lbf ft) Loctite® 243™
Hose clamp, intake flange M4 1.5 Nm (1.11 lbf ft) –
Oil jet, conrod lubrication M4 2 Nm (1.5 lbf ft) Loctite® 243™
Locking screw for bearing M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, breather cover on valve cover M5 3 Nm (2.2 lbf ft) Loctite® 243™
Screw, clutch spring M5 6 Nm (4.4 lbf ft) –
Screw, cover plate for oil return line M5 6 Nm (4.4 lbf ft) –
Screw, gear sensor M5 5 Nm (3.7 lbf ft) Loctite® 243™
Screw, oil filter cover M5 6 Nm (4.4 lbf ft) –
Screw, oil pump cover M5 6 Nm (4.4 lbf ft) Loctite® 243™
Plug, vacuum connection M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, Autodecompression M6 3… 4 Nm (2.2… 3 lbf ft) Loctite® 243™
Screw, axial lock of camshaft M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, clutch cover M6 10 Nm (7.4 lbf ft) –
Screw, clutch slave cylinder M6x20 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, clutch slave cylinder M6x35 10 Nm (7.4 lbf ft) –
Screw, cylinder M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, cylinder head M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, engine housing M6 10 Nm (7.4 lbf ft) –
Screw, generator cover M6 10 Nm (7.4 lbf ft) –
Screw, generator cover (chain shaft M6 10 Nm (7.4 lbf ft) Loctite® 243™
through-hole)
Screw, ignition pulse generator M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, locking lever M6 10 Nm (7.4 lbf ft) Loctite® 243™

Screw, rocker arm shaft M6 12 Nm (8.9 lbf ft) –
Screw, shift drum locating M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, shift lever M6 10 Nm (7.4 lbf ft) Loctite® 222
Screw, starter motor M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, stator bracket M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, thermostat housing M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, timing chain guide rail M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, timing chain tensioning rail M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, valve cover M6 10 Nm (7.4 lbf ft) –
Screw, water pump cover M6 10 Nm (7.4 lbf ft) –
Screw, water pump wheel M6 10 Nm (7.4 lbf ft) Loctite® 243™
Oil jet, piston cooling M6x0.75 4 Nm (3 lbf ft) Loctite® 243™
Plug, crankshaft location M8 20 Nm (14.8 lbf ft) –
Stud, exhaust flange M8 10 Nm (7.4 lbf ft) Loctite® 243™
Cylinder head screw M10 Tightening sequence: lubricated with engine oil
Tighten diagonally, beginning
with the rear screw on the
chain shaft.
Step 1
15 Nm (11.1 lbf ft)
Step 2
30 Nm (22.1 lbf ft)
Step 3
45 Nm (33.2 lbf ft)
Step 4
60 Nm (44.3 lbf ft)
Oil hole plug M10x1 15 Nm (11.1 lbf ft) Loctite® 243™

Plug, drain hole of water pump M10x1 15 Nm (11.1 lbf ft) –
Plug, oil bore for oil radiator M10x1 15 Nm (11.1 lbf ft) –
Screw, unlocking of timing chain ten- M10x1 10 Nm (7.4 lbf ft) –
sioner
Spark plug M12x1.25 17 Nm (12.5 lbf ft) –
Coolant temperature sensor on cylinder M12x1.5 12 Nm (8.9 lbf ft) –
head
Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –
Oil pressure regulator valve plug M12x1.5 20 Nm (14.8 lbf ft) –
Plug, oil bore M14x1.5 15 Nm (11.1 lbf ft) Loctite® 243™
Engine case stud M16x1.5 25 Nm (18.4 lbf ft) Loctite® 243™
Rotor nut M18x1.5 100 Nm (73.8 lbf ft) –
Nut, engine sprocket M20x1.5 60 Nm (44.3 lbf ft) Loctite® 243™
Nut, inner clutch hub M20x1.5 100 Nm (73.8 lbf ft) Loctite® 243™
Nut, primary gear M20LHx1.5 90 Nm (66.4 lbf ft) Loctite® 243™
Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) –
Plug, timing chain tensioner M20x1.5 25 Nm (18.4 lbf ft) –
Plug, oil thermostat M24x1.5 15 Nm (11.1 lbf ft) –
Screw in generator cover M24x1.5 8 Nm (5.9 lbf ft) –
TECHNICAL DATA - CHASSIS 152
Frame Lattice frame made of chrome molybdenum steel tubing, powder-

coated
Fork WP Suspension Up Side Down 4860 ROMA
Shock absorber WP Suspension 4618 with Pro‑Lever deflector
Suspension travel
Front 140 mm (5.51 in)
Rear 140 mm (5.51 in)
Brake system
Front Disc brake with radially screwed four-piston brake caliper, floating
brake disc
Rear Disc brake with single-piston brake caliper, floating
Brake discs - diameter
Front 320 mm (12.6 in)
Rear 240 mm (9.45 in)
Brake discs - wear limit
Front 3.6 mm (0.142 in)
Rear 4.5 mm (0.177 in)
Tire air pressure, Solo
Tire air pressure with passenger / fully loaded
Secondary drive ratio 16:40
Chain 5/8 x 1/4” X‑ring
Steering head angle 63.5°

Wheelbase 1,472±15 mm (57.95±0.59 in)
Seat height unloaded 865 mm (34.06 in)
Ground clearance unloaded 155 mm (6.1 in)
Weight without fuel approx. 148.5 kg (327.4 lb.)
Maximum permissible front axle load 150 kg (331 lb.)
Maximum permissible rear axle load 200 kg (441 lb.)
Maximum permissible overall weight 350 kg (772 lb.)
Battery YTZ10S Battery voltage: 12 V

Nominal capacity: 8.6 Ah
maintenance-free
Fuse 58011109130 30 A
Fuse 75011088015 15 A
Fuse 75011088010 10 A
Lighting equipment
17.1
Low beam/high beam HB3/P20d 12 V

60 W
Parking light W2.1x9.5d 12 V
5W
Instrument lights and indicator lamps LED
Flasher light BAU15s 12 V
10 W
Brake/tail light LED
License plate lamp W2.1x9.5d 12 V

5W
Front tire Rear tire

120/70 R 17 M/C 58H TL 160/60 R 17 M/C 69H TL
Dunlop Sportmax GPR Alpha 10 Dunlop Sportmax GPR Alpha 10
Additional information is available in the Service section under:
http://www.ktm.com
Capacity - fuel
17.2
Total fuel tank capacity, approx. 13.5 l (3.57 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. 165)
Fuel reserve, approx. 2.5 l (2.6 qt.)

TECHNICAL DATA - FORK 155
Fork part number 14.18.7E.09

Fork WP Suspension Up Side Down 4860 ROMA
Compression damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Rebound damping
Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Spring length with preload spacer(s) 352 mm (13.86 in)
Spring rate
Weight of rider: 75… 85 kg (165… 187 lb.) 7.5 N/mm (42.8 lb/in)
Air chamber length 120+10 +0.39
−30 mm (4.72−1.18 in)
Fork length 850 mm (33.46 in)
Fork oil 760 ml (25.7 fl. oz.) Fork oil (SAE 5) ( p. 164)
TECHNICAL DATA - SHOCK ABSORBER 156
Shock absorber part number 15.18.7E.09

Shock absorber WP Suspension 4618 with Pro‑Lever deflector
Compression damping, high-speed
Comfort 2.5 turns
Standard 2.0 turns
Sport 1.5 turns
Full payload 1.5 turns
Compression damping, low-speed
Comfort 25 clicks
Standard 20 clicks
Sport 15 clicks
Rebound damping
Comfort 20 clicks
Standard 15 clicks
Sport 10 clicks
Spring preload
Comfort 12 mm
Standard 12 mm
Sport 12 mm
Full payload 15 mm
Spring rate
Weight of rider: 75… 85 kg (165… 187 lb.) 70 N/mm (400 lb/in)
Spring length 185 mm (7.28 in)
TECHNICAL DATA - SHOCK ABSORBER 157
Gas pressure 10 bar (145 psi)

Static sag 25 mm (0.98 in)
Riding sag 60… 65 mm (2.36… 2.56 in)
Fitted length 376 mm (14.8 in)
Shock absorber fluid Shock absorber oil (SAE 2.5) (50180342S1) ( p. 164)
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 158
Screw, combination instrument 1 Nm (0.7 lbf ft) –

Screw, combination instrument holder 1 Nm (0.7 lbf ft) –
Remaining screws, chassis M4 4 Nm (3 lbf ft) –
Screw, side stand switch M4 2 Nm (1.5 lbf ft) Loctite® 243™
Remaining screws, chassis M5 4 Nm (3 lbf ft) –
Screw, footbrake pedal foothold M5 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, fuel level indicator M5 3 Nm (2.2 lbf ft) –
Screw, fuel pump M5 4 Nm (3 lbf ft) –
Screw, plastic clamp of brake line on M5 2 Nm (1.5 lbf ft) –
fork leg
Screw, pressure regulator M5 4 Nm (3 lbf ft) –
Screw, seat lock M5 3 Nm (2.2 lbf ft) Loctite® 222
Screw, side cover M5 2 Nm (1.5 lbf ft) –
Screw, starter cable on starter M5 3 Nm (2.2 lbf ft) –
Lower radiator bracket nut M6 5 Nm (3.7 lbf ft) –
Remaining nuts, chassis M6 15 Nm (11.1 lbf ft) –
Remaining screws on fuel tank M6 6 Nm (4.4 lbf ft) –
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –
Screw, ball joint of push rod on foot- M6 10 Nm (7.4 lbf ft) Loctite® 243™
brake cylinder
Screw, battery holder M6 3 Nm (2.2 lbf ft) –
Screw, brake fluid reservoir of rear brake M6 5 Nm (3.7 lbf ft) –
Screw, bug spoiler M6 7 Nm (5.2 lbf ft) –
Screw, control unit holder M6 3 Nm (2.2 lbf ft) –
Screw, footbrake cylinder M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, fuel tap M6 Tightening sequence: –

tighten in parallel
6 Nm (4.4 lbf ft)
Screw, headlight mask M6 5 Nm (3.7 lbf ft) –
Screw, horn M6 6 Nm (4.4 lbf ft) Loctite® 243™
Screw, license plate holder M6 8 Nm (5.9 lbf ft) –
Screw, lower radiator bracket M6 5 Nm (3.7 lbf ft) –
Screw, magnetic holder on side stand M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, side stand bracket M6 10 Nm (7.4 lbf ft) Loctite® 243™
Screw, SLS valve M6 6 Nm (4.4 lbf ft) –
Screw, voltage regulator/rectifier M6 8 Nm (5.9 lbf ft) –
Nut, manifold on cylinder head M8 25 Nm (18.4 lbf ft) Copper paste
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite® 243™
Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) –
Screw, fork stub M8 15 Nm (11.1 lbf ft) –
Screw, front brake disc M8 30 Nm (22.1 lbf ft) Loctite® 243™
Screw, fuel tank bracket M8 15 Nm (11.1 lbf ft) –
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –
Screw, handrail M8 6 Nm (4.4 lbf ft) –
Screw, ignition lock M8 Loctite® 243™
Screw, linkage bracket, front engine M8 25 Nm (18.4 lbf ft) Loctite® 243™
bracket
Screw, main silencer fixation M8 25 Nm (18.4 lbf ft) –
Screw, manifold on main silencer M8 25 Nm (18.4 lbf ft) Copper paste

Screw, rear brake disc M8 30 Nm (22.1 lbf ft) Loctite® 243™
Screw, rear footrest bracket M8 25 Nm (18.4 lbf ft) Loctite® 243™
Screw, side stand bracket M8 25 Nm (18.4 lbf ft) Loctite® 243™
Screw, spring holder on side stand M8 15 Nm (11.1 lbf ft) Loctite® 243™
bracket
Screw, steering stem M8 20 Nm (14.8 lbf ft) –
Screw, top triple clamp M8 12 Nm (8.9 lbf ft) –
Screw, upper subframe M8 35 Nm (25.8 lbf ft) Loctite® 243™
Engine carrying screw M10 45 Nm (33.2 lbf ft) Loctite® 243™
Screw, bottom shock absorber M10 45 Nm (33.2 lbf ft) Loctite® 243™
Screw, foot brake pedal M10 25 Nm (18.4 lbf ft) –
Screw, handlebar support M10 20 Nm (14.8 lbf ft) –
Screw, side stand M10 35 Nm (25.8 lbf ft) Loctite® 243™
Screw, top shock absorber M10 45 Nm (33.2 lbf ft) Loctite® 243™
Screw, front brake caliper M10x1.25 45 Nm (33.2 lbf ft) Loctite® 243™
Screw, lower subframe M10x1.25 45 Nm (33.2 lbf ft) Loctite® 243™
Lambda probe M12x1.25 24.5 Nm (18.07 lbf ft) –
Nut, frame to linkage lever M14x1.5 100 Nm (73.8 lbf ft) –
Nut, linkage lever on swingarm M14x1.5 100 Nm (73.8 lbf ft) –
Nut, linkage lever to rocker arm M14x1.5 100 Nm (73.8 lbf ft) –
Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) –
Screw, steering head M20x1.5 12 Nm (8.9 lbf ft) –

Adjusting ring of swingarm bearing M24x1.5 25 Nm (18.4 lbf ft) –
Screw, front wheel spindle M24x1.5 40 Nm (29.5 lbf ft) –
Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) –
SUBSTANCES 162
Brake fluid DOT 4 / DOT 5.1

According to
– DOT
Guideline
– Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre-
sponding properties. KTM recommends Castrol and Motorex® products.
Supplier
Castrol
– RESPONSE BRAKE FLUID SUPER DOT 4
Motorex®
– Brake Fluid DOT 5.1
Coolant
Guideline
– Use only suitable coolant (in countries with high temperatures also). Use of low-quality antifreeze can lead to corrosion and foaming.
KTM recommends Motorex® products.
Mixture ratio
Antifreeze protection: −25… −45 °C (−13… 50 % Corrosion/antifreeze
−49 °F) 50 % Distilled water
Coolant (mixed ready to use)

Antifreeze −40 °C (−40 °F)
Supplier
Motorex®
– Anti Freeze
SUBSTANCES 163
Engine oil (SAE 10W/60) (00062010035)

According to
– JASO T903 MA ( p. 168)
– SAE ( p. 168) (SAE 10W/60)
– KTM LC4 2007+
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding
properties. KTM recommends Motorex® products.
Synthetic engine oil
Supplier
Motorex®
– Motorex® KTM Cross Power 4T
Engine oil (SAE 10W/50)

According to
– JASO T903 MA ( p. 168)
– SAE ( p. 168) (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. KTM recommends Motorex® products.
Fully synthetic engine oil
Supplier
Motorex®
– Power Synt 4T
SUBSTANCES 164
Fork oil (SAE 5)

According to
– SAE ( p. 168) (SAE 5)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that possesses the corresponding prop-
erties. KTM recommends Motorex® products.
Supplier
Motorex®
– Racing Fork Oil
Hydraulic fluid (15)

According to
– ISO VG (15)
Guideline
– Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the corre-
sponding properties. KTM recommends Motorex® products.
Supplier
Motorex®
– Hydraulic Fluid 75
Shock absorber oil (SAE 2.5) (50180342S1)

According to
– SAE ( p. 168) (SAE 2.5)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding proper-
ties.
SUBSTANCES 165
Super unleaded (ROZ 95 / RON 95 / PON 91)

According to
– DIN EN 228 (ROZ 95 / RON 95 / PON 91)
AUXILIARY SUBSTANCES 166
Chain cleaner
Specification
– KTM recommends Motorex® products.
Supplier
Motorex®
– Chain Clean 611
Cleaning and polishing materials for metal, rubber and plastic

Specification
Supplier
Motorex®
– Protect & Shine 645
Contact spray
Specification
Supplier
Motorex®
– Accu Contact
High-luster polish for paint

Specification
Supplier
Motorex®
– Moto Polish
AUXILIARY SUBSTANCES 167
Long-life grease
Specification
Supplier
Motorex®
– Fett 2000
Motorcycle cleaner
Specification
Supplier
Motorex®
– Moto Clean 900
Onroad chain spray

Specification
Supplier
Motorex®
– Chain Lube 622 Strong
Universal oil spray

Specification
Supplier
Motorex®
– Joker 440 Universal
STANDARDS 168
JASO T903 MA
Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear-
lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification.
Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for
motorcycle engines. With most motorcycles, the gearbox and the clutch are lubricated with the same oil as the engine. The JASO MA Stan-
dard meets these special requirements.
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscos-
ity. The viscosity describes only one property of oil and says nothing about quality.
INDEX 169
checking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

INDEX
A
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Antifreeze Chain tension

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
B
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Baggage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142-143
Battery
Clutch
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
fluid level, checking/rectifying . . . . . . . . . . . . . . . . . . . 123
recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . . 122
Brake discs
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Combination instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Brake fluid
function buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
ODO display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Brake fluid level setting clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 71 setting kilometers or miles . . . . . . . . . . . . . . . . . . . . . . . 27
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 setting/resetting TRIP 1 . . . . . . . . . . . . . . . . . . . . . . . . . 29
Brake linings setting/resetting TRIP 2 . . . . . . . . . . . . . . . . . . . . . . . . . 30
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 73 speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 temperature indicator of coolant . . . . . . . . . . . . . . . . . . . 31
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TRIP F display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
C
Conservation for winter operation . . . . . . . . . . . . . . . . . . . . . 144
Chain
checking for dirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
INDEX 170
Coolant F
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Filler cap
Coolant level closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115, 118 opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Filling up
filling/bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
D Flasher bulb
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
E Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Electric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Flashing code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137-141
Emergency OFF switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Engine checking free play . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Engine characteristic compression damping, adjusting . . . . . . . . . . . . . . . . . . . 58
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 fork legs, bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
rebound, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fork part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine oil
adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Front wheel
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Fuel tank
Engine oil level positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 reinstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Fuel taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INDEX 171
Fuse Loading the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

power consumers, changing . . . . . . . . . . . . . . . . . . . . . . 96 Low beam bulb
H changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 M

basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 71 Main fuse
Handrails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Headlight adjustment Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
high beam, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 113 Motorcycle
high beam, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 111 cleaning . . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . 142
low beam, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 112 jacking up front . . . . . . . . .... . . . . . . . . . . . . . . . . . . 56
low beam, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 110 jacking up rear . . . . . . . . . .... . . . . . . . . . . . . . . . . . . 57
Headlight flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 taking front from work stand ... . . . . . . . . . . . . . . . . . . 56
Headlight mask with headlight taking rear from work stand .... . . . . . . . . . . . . . . . . . . 57
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 O
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Oil filter
High beam bulb changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
I Oil screen
Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Oil screens
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
K
Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Owner's manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
L
P
Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INDEX 172
Parking light bulb Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53-55

changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Passenger footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Play in gas Bowden cable Shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 compression damping, general . . . . . . . . . . . . . . . . . . . . 60
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 compression damping, high-speed, adjusting . . . . . . . . . . 61
compression damping, low-speed, adjusting . . . . . . . . . . . 60
Protection for winter operation . . . . . . . . . . . . . . . . . . . . . . . 144
rebound damping, adjusting . . . . . . . . . . . . . . . . . . . . . . 62
Putting into operation
Shock absorber part number . . . . . . . . . . . . . . . . . . . . . . . . . 18
advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
checks before putting into operation . . . . . . . . . . . . . . . . 42
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
R Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Rear hub rubber dampers Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Rear sprocket / engine sprocket T
checking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Rear wheel Technical data
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 chassis . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 152-154
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 chassis tightening torques . . . . . . . . . . . . . . . . . . 158-161
Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 engine . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 147-148
starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 engine tightening torques . . . . . . . . . . . . . . . . . . 149-151
fork . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 155
S
shock absorber . . . . . . . .. . . . . . . . . . . . . . . . . . 156-157
Seat
Tire air pressure
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Seat lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INDEX 173
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Tool set . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Transport . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Troubleshooting .. . . . . . . . . . . . . . . . . . . . . . . . . . . 134-136
Type label . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
U
Use definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
V
View of vehicle
front left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
right rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Work rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
*3211370en*
3211370en
10/2008 Photo: Mitterbauer
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com

KTM 690 Duke 2009 Manual UK

Uploaded by

Copyright:

Available Formats

KTM 690 Duke 2009 Manual UK

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

KTM 690 Duke 2009 Manual UK

Uploaded by

Copyright:

Available Formats

What does the manual cover?

What does the manual cover?

What information is provided about the vehicle?

What information is provided about the vehicle?

OWNER'S MANUAL 2009

enormous pleasure if you service and maintain it accordingly.

We wish you great pleasure riding the vehicle!

Enter the serial numbers of your vehicle below.

Engine number ( p. 17)

Key number ( p. 16)

© 2008 by KTM-Sportmotorcycle AG, Mattighofen Austria

ISO 9001(12 100 6061)

Setting the clock .............................................................. 28

MEANS OF REPRESENTATION ............................................... 6

Refueling......................................................................... 51 Adding front brake fluid x............................................... 72

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

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

Name® Identifies a protected name.

Brand™ Identifies a trademark.

Fuel, oils, etc.

Spare parts, accessories

– Switch off the engine and remove the ignition key.

View of vehicle, front left side

View of vehicle, rear right

Chassis number/type label

The chassis number  is stamped on the right of the steering head.

The key number  can be found on the KEYCODECARD.

Fork part number

Shock absorber part number

The clutch lever  is fitted on the left side of the handlebar.

Hand brake lever

The light switch  is fitted on the left side of the handlebar.

Headlight flasher switch

The flasher switch  is fitted on the left side of the handlebar.

The horn button  is fitted on the left side of the handlebar.

The ignition/steering lock  is in front of the upper triple clamp.

Emergency OFF switch

Emergency OFF switch on – This position is necessary for operation as the

Electric starter button

The combination instrument is installed in front of the handlebar.

Combination instrument - function buttons

Combination instrument - tachometer

The tachometer  shows the engine speed in revolutions per minute.

Combination instrument - indicator lamps

The idle speed indicator lamp lights up green – The transmission is

Temperature warning lamp lights up red – Coolant has reached a critical

Combination instrument - display

The display then changes to the last selected mode.

Combination instrument - speedometer

Setting kilometers or miles

– Switch on the ignition by turning the ignition key to the position .

Combination instrument - time

The time is shown in area  of the display.

Setting the clock

– Switch on the ignition by turning the ignition key to the position .

Combination instrument - display ODO

Combination instrument - setting/resetting TRIP 1

– Switch on the ignition by turning the ignition key to the position .

Combination instrument - setting/resetting TRIP 2

– Switch on the ignition by turning the ignition key to the position .