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OWNER'S MANUAL 2021
350 EXC-F
Art. no. 3214225en
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DEAR KTM CUSTOMER
DEARKTM CUSTOMER
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art,
sporty motorcycle that you will continue to enjoy for a long time if you maintain it properly.
We wish you good and safe riding at all times!
Please enter the serial number of your vehicle below.
Vehicle identification number ( p. 17) Stamp of dealer
Engine number ( p. 18)
Key number ( p. 17)
The Owner's Manual contained the latest information for this model series at the time of going to print. Slight
deviations resulting from continuing development and design of the motorcycles can, however, not be completely
excluded.
All specifications contained herein are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right
to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc.,
without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from figures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that
does not belong to the regular scope of supply.
© 2020 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission
of the copyright owner.
ISO 9001(12 100 6061)
KTM applies quality assurance processes that lead to the highest possible product quality as
defined in the ISO 9001 international quality management standard.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
350 EXC‑F US (F8275U9)
*3214225en*
3214225en
05/2020
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TABLE OF CONTENTS
TABLEOF CONTENTS
1 MEANS OF REPRESENTATION ...................... 6
1.1 Symbols used .................................... 6
1.2 Formats used..................................... 6
2 SAFETY ADVICE............................................ 7
2.1 Use definition – intended use.............. 7
2.2 Misuse.............................................. 7
2.3 Safety advice..................................... 7
2.4 Degrees of risk and symbols ................ 7
2.5 Overview of labels .............................. 8
2.6 Reporting safety defects ................... 10
2.7 Noise emission warranty ................... 10
2.8 Operating noise warning ................... 10
2.9 Manufacturer warranty for the
exhaust monitoring system................ 10
2.10 Consumer rights............................... 11
2.11 Tampering warning........................... 11
2.12 Safe operation ................................. 11
2.13 Protective clothing ........................... 12
2.14 Work rules ....................................... 12
2.15 Environment.................................... 12
2.16 Owner's Manual ............................... 13
3 IMPORTANT NOTES.................................... 14
3.1 Manufacturer and implied warranty.... 14
3.2 Fuel, auxiliary substances ................. 14
3.3 Spare parts, accessories ................... 14
3.4 Service ........................................... 14
3.5 Figures ........................................... 14
3.6 Customer service.............................. 14
4 VIEW OF VEHICLE ...................................... 15
4.1 View of vehicle, front left (example) ... 15
4.2 View of vehicle, rear right
(example)........................................ 16
5 SERIAL NUMBERS ..................................... 17
5.1 Vehicle identification number............ 17
5.2 Type label ....................................... 17
5.3 Key number..................................... 17
5.4 Engine number ................................ 18
5.5 Fork part number ............................. 18
5.6 Shock absorber article number .......... 18
6 CONTROLS................................................. 19
6.1 Clutch lever..................................... 19
6.2 Hand brake lever.............................. 19
6.3 Throttle grip .................................... 19
6.4 Horn button..................................... 19
6.5 Light switch .................................... 20
6.6 Turn signal switch............................ 20
6.7 Emergency OFF switch ..................... 20
6.8 Start button..................................... 20
6.9 Overview of indicator lamps .............. 21
6.10 Ignition lock .................................... 21
6.11 Opening the fuel tank filler cap ......... 21
6.12 Closing the fuel tank filler cap........... 22
6.13 Cold start button.............................. 22
6.14 Idle speed adjusting screw................ 23
6.15 Shift lever ....................................... 23
6.16 Foot brake lever ............................... 24
6.17 Side stand....................................... 24
6.18 Steering lock ................................... 24
6.19 Locking the steering......................... 25
6.20 Unlocking the steering...................... 25
7 COMBINATION INSTRUMENT ..................... 26
7.1 Combination instrument overview ...... 26
7.2 Activation and test ........................... 26
7.3 Setting the kilometers or miles .......... 26
7.4 Setting the combination instrument ... 27
7.5 Setting the clock.............................. 28
7.6 Viewing the lap time......................... 28
7.7 Display mode SPEED (speed) ............ 29
7.8 Display mode SPEED/H (operating
hours)............................................. 29
7.9 Setup menu .................................... 29
7.10 Setting the unit of measurement ....... 30
7.11 Display mode SPEED/CLK (time)....... 31
7.12 Setting the clock.............................. 31
7.13 Display mode SPEED/LAP (lap
time) .............................................. 31
7.14 Viewing the lap time......................... 32
7.15 Display mode SPEED/ODO
(odometer) ...................................... 32
7.16 Display mode SPEED/TR1 (trip
master 1) ........................................ 33
7.17 Display mode SPEED/TR2 (trip
master 2) ........................................ 33
7.18 Setting TR2 (trip master 2) ............... 33
7.19 Display mode SPEED/A1 (average
speed 1) ......................................... 34
7.20 Display mode SPEED/A2 (average
speed 2) ......................................... 34
7.21 Display mode SPEED/S1 (stop
watch 1) ......................................... 35
7.22 Display mode SPEED/S2 (stop
watch 2) ......................................... 35
7.23 Table of functions............................ 36
7.24 Table of conditions and menu
activation ........................................ 37
8 PREPARING FOR USE................................. 38
8.1 Advice on preparing for first use ........ 38
8.2 Running-in the engine ...................... 39
8.3 Starting power of lithium-ion
batteries at low temperatures ............ 40
8.4 Preparing the vehicle for difficult
operating conditions......................... 40
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TABLE OF CONTENTS
8.5 Preparing the vehicle for riding on
dry sand.......................................... 40
8.6 Preparing the vehicle for riding on
wet sand ......................................... 41
8.7 Preparing the vehicle for riding on
wet and muddy circuits .................... 42
8.8 Preparing vehicle for high
temperatures or slow riding ............... 42
8.9 Preparing the vehicle for low
temperatures or snow ....................... 42
9 RIDING INSTRUCTIONS.............................. 43
9.1 Checks and maintenance measures
when preparing for use ..................... 43
9.2 Starting the vehicle .......................... 43
9.3 Starting off...................................... 44
9.4 Shifting, riding ................................ 44
9.5 Braking........................................... 45
9.6 Stopping, parking............................. 45
9.7 Transporting.................................... 46
9.8 Refueling ........................................ 46
10 SERVICE SCHEDULE .................................. 48
10.1 Additional information ...................... 48
10.2 Required work ................................. 48
10.3 Recommended work ......................... 49
11 TUNING THE CHASSIS ............................... 51
11.1 Checking the basic chassis setting
with rider's weight............................ 51
11.2 Compression damping of the shock
absorber.......................................... 51
11.3 Adjusting the low-speed
compression damping of the shock
absorber.......................................... 51
11.4 Adjusting the high-speed
compression damping of the shock
absorber.......................................... 52
11.5 Adjusting the rebound damping of
the shock absorber ........................... 53
11.6 Measuring the dimension of the rear
wheel unloaded................................ 53
11.7 Checking the static sag of the shock
absorber.......................................... 54
11.8 Checking the riding sag of the shock
absorber.......................................... 54
11.9 Adjusting the spring preload of the
shock absorber ............................. 55
11.10 Adjusting the riding sag ................ 56
11.11 Checking the basic setting of the
fork ................................................ 56
11.12 Adjusting the compression damping
of the fork ....................................... 57
11.13 Adjusting the rebound damping of
the fork........................................... 57
11.14 Handlebar position ........................... 58
11.15 Adjusting the handlebar position .... 58
12 SERVICE WORK ON THE CHASSIS............... 60
12.1 Raising the motorcycle with the lift
stand .............................................. 60
12.2 Removing the motorcycle from the
lift stand ......................................... 60
12.3 Bleeding the fork legs....................... 60
12.4 Cleaning the dust boots of the fork
legs ................................................ 61
12.5 Removing the fork protector .............. 61
12.6 Installing the fork protector............... 62
12.7 Removing the fork legs .................. 62
12.8 Installing the fork legs .................. 63
12.9 Removing the lower triple clamp .... 63
12.10 Installing the lower triple clamp ..... 64
12.11 Checking the steering head bearing
play ................................................ 66
12.12 Adjusting the steering head bearing
play ............................................ 67
12.13 Lubricating the steering head
bearing ........................................ 67
12.14 Removing front fender...................... 68
12.15 Installing front fender....................... 68
12.16 Removing the shock absorber ........ 69
12.17 Installing the shock absorber ......... 69
12.18 Removing the seat ........................... 69
12.19 Mounting the seat ............................ 70
12.20 Removing the air filter box cover ....... 70
12.21 Installing the air filter box cover ........ 71
12.22 Removing the air filter .................. 72
12.23 Installing the air filter ................... 72
12.24 Cleaning the air filter and air filter
box ............................................. 73
12.25 Preparing air filter box cover for
securing ...................................... 73
12.26 Removing the main silencer .............. 74
12.27 Installing the main silencer............... 74
12.28 Cleaning the spark arrestor ............ 74
12.29 Changing the glass fiber yarn filling
of the main silencer ...................... 76
12.30 Removing the fuel tank ................. 76
12.31 Installing the fuel tank .................. 78
12.32 Checking for chain dirt
accumulation................................... 79
12.33 Cleaning the chain ........................... 80
12.34 Checking the chain tension ............... 80
12.35 Adjusting the chain tension............... 81
12.36 Checking the chain, rear sprocket,
engine sprocket, and chain guide ...... 82
12.37 Checking the frame ...................... 85
12.38 Checking the link fork ................... 85
12.39 Checking throttle cable routing.......... 85
12.40 Checking the rubber grip .................. 86
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12.41 Adjusting the basic position of the
clutch lever ..................................... 86
12.42 Checking/correcting the fluid level of
the hydraulic clutch ......................... 87
12.43 Changing the hydraulic clutch
fluid ............................................ 88
13 BRAKE SYSTEM ......................................... 90
13.1 Checking the free travel of the hand
brake lever ...................................... 90
13.2 Adjusting the free travel of the
handbrake lever ............................... 90
13.3 Checking the brake discs .................. 90
13.4 Checking the front brake fluid level ... 91
13.5 Adding the front brake fluid ........... 92
13.6 Checking the front brake linings ........ 93
13.7 Changing the brake linings of the
front brake ................................... 93
13.8 Checking the free travel of foot brake
lever ............................................... 95
13.9 Adjusting the basic position of the
foot brake lever ............................ 96
13.10 Checking the rear brake fluid level..... 96
13.11 Adding rear brake fluid ................. 97
13.12 Checking the rear brake linings ......... 98
13.13 Changing the rear brake linings ...... 98
14 WHEELS, TIRES ....................................... 101
14.1 Removing the front wheel ............ 101
14.2 Installing the front wheel ............ 102
14.3 Removing the rear wheel ............. 102
14.4 Installing the rear wheel .............. 103
14.5 Checking the tire condition ............. 105
14.6 Checking tire pressure .................... 105
14.7 Checking spoke tension .................. 106
15 ELECTRICAL SYSTEM ............................... 107
15.1 Removing the 12-V battery .......... 107
15.2 Installing the 12-V battery ........... 108
15.3 Charging the 12-V battery ........... 109
15.4 Changing the main fuse.................. 111
15.5 Changing the fuses of individual
power consumers ........................... 112
15.6 Removing the headlight mask with
the headlight ................................. 113
15.7 Installing the headlight mask with
the headlight ................................. 114
15.8 Changing the headlight bulb ........... 114
15.9 Checking the headlight setting ........ 115
15.10 Adjusting the headlight range.......... 115
15.11 Changing the turn signal bulb ......... 116
15.12 Changing the combination
instrument battery.......................... 117
15.13 Diagnostics connector .................... 118
16 COOLING SYSTEM .................................... 119
16.1 Cooling system .............................. 119
16.2 Checking the antifreeze and
coolant level.................................. 119
16.3 Checking the coolant level .............. 120
16.4 Draining the coolant ................... 120
16.5 Refilling coolant ......................... 121
16.6 Changing the coolant...................... 122
17 TUNING THE ENGINE............................... 123
17.1 Checking the throttle cable play ...... 123
17.2 Adjusting the throttle cable
play .......................................... 123
17.3 Adjusting the characteristic map of
the throttle response ................... 124
17.4 Adjusting the idle speed .............. 125
17.5 Teaching the throttle valve
position......................................... 126
17.6 Checking the basic position of the
shift lever...................................... 127
17.7 Adjusting the basic position of the
shift lever .................................. 127
18 SERVICE WORK ON THE ENGINE .............. 128
18.1 Changing the fuel screen ............. 128
18.2 Checking the engine oil level........... 129
18.3 Changing the engine oil and oil
filter, cleaning the oil screen ....... 129
18.4 Adding engine oil ........................... 132
19 CLEANING, CARE ..................................... 133
19.1 Cleaning the motorcycle ................. 133
19.2 Checks and maintenance steps for
winter operation............................. 134
20 STORAGE................................................. 135
20.1 Storage ......................................... 135
20.2 Preparing for use after storage......... 136
21 TROUBLESHOOTING ................................ 137
22 BLINK CODE ............................................ 139
23 TECHNICAL DATA..................................... 141
23.1 Engine .......................................... 141
23.2 Engine tightening torques ............... 142
23.3 Capacities ..................................... 144
23.3.1 Engine oil ................................. 144
23.3.2 Coolant..................................... 144
23.3.3 Fuel ......................................... 144
23.4 Chassis ......................................... 144
23.5 Electrical system............................ 145
23.6 Tires ............................................. 145
23.7 Fork.............................................. 146
23.8 Shock absorber .............................. 146
23.9 Chassis tightening torques .............. 147
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24 SUBSTANCES .......................................... 149
25 AUXILIARY SUBSTANCES ......................... 151
26 STANDARDS ............................................ 153
27 INDEX OF SPECIAL TERMS ....................... 154
28 LIST OF ABBREVIATIONS.......................... 155
29 LIST OF SYMBOLS.................................... 156
29.1 Yellow and orange symbols.............. 156
29.2 Green and blue symbols.................. 156
INDEX ............................................................. 157
TABLE OF CONTENTS
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1 MEANS OF REPRESENTATION
1.1 Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding.
In the interest of your own safety, have these jobs performed by an authorized KTM workshop!
Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary
tools required.
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates the end of an activity, including potential rework.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
®
Name
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which
Indicates a protected name.
are explained in the glossary.
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SAFETY ADVICE 2
2.1 Use definition – intended use
This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations.
Info
This vehicle is only authorized for operation on public roads in the homologated (restricted) version.
The derestricted version of this vehicle must only be operated in closed off areas away from public highway traffic.
This vehicle is designed for use in offroad endurance competition, and not primarily for use in motocross.
2.2 Misuse
The vehicle must only be used as intended.
Dangers can arise for people, property and the environment through use not as intended.
Any use of the vehicle beyond the intended and defined use constitutes misuse.
Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the
respective use.
2.3 Safety advice
A number of safety instructions need to be followed to operate the product described safely. Therefore read this
instruction and all further instructions included carefully. The safety instructions are highlighted in the text and
are referred to at the relevant passages.
Info
Various information and warning labels are attached in prominent locations on the product described. Do
not remove any information or warning labels. If they are missing, you or others may not recognize dangers
and may therefore be injured.
2.4 Degrees of risk and symbols
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the
appropriate measures are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not
taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are
not taken.
Note
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
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2 SAFETY ADVICE
2.5 Overview of labels
1 Canada type label
2 USA type label
3 Brake fluid information
4 Information on chain tension
5 Information on starting up
6 Information on emissions control
7 Information on noise emission
Canada type label
V01850-10
E01688-01
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USA type label
SAFETY ADVICE 2
E01691-01
Brake fluid information
S00026-10
101516-01
F00491-10
Information on chain tension
Information on starting up
Information on emissions control
E01690-01
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2 SAFETY ADVICE
Information on noise emission
2.6 Reporting safety defects
If you believe that your vehicle has a defect which could cause an accident resulting in injury or death, you
should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying
KTM North America, Inc.
If NHTSA receives multiple similar complaints, it may open an investigation, and if it finds that a safety defect
exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become
involved in individual problems between you, your dealer, or KTM North America, Inc.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1–888–327–4236 or visit the website
www.nhtsa.dot.gov, or write to: NHTSA Headquarters, 1200 New Jersey Avenue, SE, West Building, Washington,
DC 20590. You can also obtain other information about motor vehicle safety from the Hotline.
E01689-01
2.7 Noise emission warranty
KTM warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards.
This manufacturer’s warranty extends to the first person who purchases this exhaust system for purposes other
than resale, and to all subsequent buyers.
Warranty claims should be directed to:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Phone: (440) 985-3553
www.ktmusa.com
KTM Canada, Inc., Customer Support, 8701 Rue Samuel‑Hatt, Chambly, QC J3L 6V4, Canada
Phone: (450) 441-4451
www.ktmcanada.com
2.8 Operating noise warning
This product should be checked for necessary repair or replacement parts if the motorcycle noise has increased
significantly through use. Otherwise, the owner may become subject to penalties under the applicable ordinances.
2.9 Manufacturer warranty for the exhaust monitoring system
KTM North America, Inc. guarantees that, at the time of sale, the exhaust monitoring system complies with all
the standards of the US Environmental Protection Agency (EPA) and the California Air Resources Board (CARB).
This manufacturer warranty applies in respect of the first owner of the motorcycle and all subsequent owners.
Your exhaust monitoring system may include parts, such as the fuel injection system, ignition, catalytic converter,
control units, hoses, connectors and other emission related assemblies, fuel tank, crankcase breather, fuel tank
lid for vehicles with fuel evaporation monitoring, oil filler cap, pressure control valve, fuel/vapor separator, canister, ignition coils, ignition wire, capacitors, and spark plugs, if a fault occurs before the first scheduled replacement and includes the hoses, fittings, and pipes that are used directly in these components.
If the warranty conditions are met, KTM will repair your motorcycle for you free of charge, including diagnosis,
parts, and labor.
As the owner of the motorcycle, you are responsible for the required maintenance specified in the Owner's Manual.
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SAFETY ADVICE 2
Please note that KTM is entitled to reject warranty claims if your motorcycle or a part fails due to misuse, negligence, an accident, participation in racing or similar events, improper maintenance or unauthorized modifications.
Scope of the manufacturer’s warranty
– Five (5) years or 30,000 kilometers (18,641 miles), whichever occurs first.
If you have any questions regarding the manufacturer warranty for the exhaust monitoring system, please address
these to:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Phone: (888) 985-6090
U.S. Environmental Protection Agency, 2000 Traverwood Drive, Ann Arbor, MI 48105, USA
California Air Resources Board, 1001 "I" Street, Sacramento, CA 95814, USA
2.10 Consumer rights
Warranty claims must be submitted to an authorized KTM workshop. If you are not satisfied, please contact:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Phone: (440) 985-3553
www.ktmusa.com
KTM Canada, Inc., Customer Support, 8701 Rue Samuel‑Hatt, Chambly, QC J3L 6V4, Canada
Phone: (450) 441-4451
www.ktmcanada.com
Different rights may apply, according to national or regional legislation.
2.11 Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing
thereof:
1 The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replace-
ment, of any device or element of design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use, or
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any
person.
Among those acts presumed to constitute tampering are the acts listed below:
1 Removal or puncturing of the main silencers, baffles, manifolds or any other components which conduct
exhaust gases.
2 Removal or puncturing of parts of the intake system.
3 Lack of proper maintenance.
4 Replacing moving parts of the vehicle, or parts of the exhaust system or intake system, with parts other than
those specified by the manufacturer.
2.12 Safe operation
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
– Do not operate the vehicle if you are physically or mentally impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
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2 SAFETY ADVICE
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system
before the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a
safe and environmentally compatible manner.
An appropriate driver's license is needed to ride the vehicle on public roads.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
2.13 Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket
with protectors on all rides.
– Always wear protective clothing that is in good condition and meets the legal regulations.
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective
clothing.
2.14 Work rules
Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models
with remote key) or the engine must be at a standstill (models without ignition lock or remote key).
Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered
using the number in parentheses. Example: bearing puller (15112017000)
During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts,
expansion screws, seals, sealing rings, O-rings, pins, and lock washers).
In the case of certain screws, a screw adhesive (e.g. Loctite®) is required. Observe the manufacturer's instructions.
If thread locker (e.g., Precote®) has already been applied to a new part, do not apply any additional thread locker.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged
or worn parts.
After completing a repair or service work, check the operating safety of the vehicle.
2.15 Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the
future of the motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and
regulations of the respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no
legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad
to advise you.
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SAFETY ADVICE 2
2.16 Owner's Manual
It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains useful information and many tips on how to operate, handle, and service your motorcycle.
Only then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself
from injury.
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed.
If you would like to know more about the vehicle or have questions on the material you read, please contact an
authorized KTM dealer.
The Owner's Manual is an important component of the vehicle and must be handed over to the new owner if the
vehicle is sold.
The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website.
International KTM Website: http://www.ktm.com
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3 IMPORTANT NOTES
3.1 Manufacturer and implied warranty
The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and confirmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused
by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.
3.2 Fuel, auxiliary substances
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use fuels and auxiliary substances in accordance with the Owner's Manual and specification.
3.3 Spare parts, accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM
and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any
resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized KTM
dealer will be glad to advise you.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4 Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work
on the engine and chassis is properly carried out as described in the Owner's Manual. An incorrect suspension
setting can lead to damage and breakage of chassis components.
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can result in significantly increased wear of components, such as the drive train, brake system, or suspension components. For this
reason, it may be necessary to inspect or replace parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly,
you will ensure a much longer service life for your motorcycle.
The relevant mileage or time interval is whichever occurs first.
3.5 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not
always necessary to disassemble the component to perform the activity in question. Please follow the instructions
in the text.
3.6 Customer service
Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.
A list of authorized KTM dealers can be found on the KTM website.
International KTM Website: http://www.ktm.com
14
Page 17
4.1 View of vehicle, front left (example)
VIEW OF VEHICLE 4
Clutch lever ( p. 19)
1
Filler cap
2
Air filter box cover
3
Side stand ( p. 24)
4
Engine number ( p. 18)
5
Shift lever ( p. 23)
6
V01848-10
15
Page 18
4 VIEW OF VEHICLE
4.2 View of vehicle, rear right (example)
Horn button ( p. 19)
1
Turn signal switch ( p. 20)
2
Light switch ( p. 20)
3
Start button ( p. 20)
4
Emergency OFF switch ( p. 20)
5
Throttle grip ( p. 19)
6
Hand brake lever ( p. 19)
7
Foot brake lever ( p. 24)
8
V01849-10
16
Page 19
5.1 Vehicle identification number
401945-10
5.2 Type label
SERIAL NUMBERS 5
The vehicle identification number1is stamped on the right side
of the steering head.
Type label1is fixed to the front of the steering head.
The additional type label for Canada2is fixed to the front of the
chest tube.
5.3 Key number
M00994-10
Key number1for the ignition and steering lock is indicated on
the KEYCODECARD.
Info
You need the key number to order a spare key. Keep
the KEYCODECARD in a safe place.
V00852-10
17
Page 20
5 SERIAL NUMBERS
5.4 Engine number
5.5 Fork part number
Engine number1is embossed on the left side of the engine over
the engine sprocket.
H01047-10
The fork part number1is stamped on the inner side of the fork
stub.
401947-10
5.6 Shock absorber article number
H02222-10
Shock absorber article number1is stamped on the top of the
shock absorber above the adjusting ring towards the engine side.
18
Page 21
6.1 Clutch lever
6.2 Hand brake lever
CONTROLS 6
Clutch lever1is fitted on the handlebar on the left.
The clutch is activated hydraulically and adjusts itself automatically.
A00345-10
The hand brake lever1is fitted on the right side of the handlebar.
The hand brake lever is used to activate the front brake.
6.3 Throttle grip
6.4 Horn button
E01205-10
The throttle grip1is fitted on the right side of the handlebar.
E01206-10
Horn button1is fitted on the left side of the handlebar.
Possible states
• The horn button is in the basic position
• The horn button is pressed – The horn is operated in this
position.
V00855-10
19
Page 22
6 CONTROLS
6.5 Light switch
6.6 Turn signal switch
V00855-11
V00855-12
The light switch1is fitted on the left side of the handlebar.
Possible states
Low beam on – The light switch is turned downward.
In this position, the low beam and tail light are
switched on.
High beam on – The light switch is turned upward.
In this position, the high beam and the tail light are
switched on.
Turn signal switch1is fitted on the left side of the handlebar.
Possible states
Turn signal light off
Turn signal light, left, on – The turn signal switch is
pressed to the left. The turn signal switch returns to
the middle position after activation.
Turn signal light, right, on – The turn signal switch is
pressed to the right. The turn signal switch returns to
the middle position after activation.
6.7 Emergency OFF switch
E01207-10
6.8 Start button
To switch off the turn signal, press the turn signal switch toward
the switch housing.
The emergency OFF switch1is fitted on the right side of the
handlebar.
Possible states
Ignition off – In this position, the ignition circuit
is interrupted, a running engine stops, and a
non-running engine will not start.
Ignition on – In this position, the ignition circuit is
closed and the engine can be started.
Start button1is fitted on the right side of the handlebar.
Possible states
• The start button is in the basic position
• The start button is pressed – The starter motor is actuated
in this position.
20
E01207-11
Page 23
6.9 Overview of indicator lamps
V01752-10
6.10 Ignition lock
V01853-10
CONTROLS 6
Possible states
The high beam indicator lamp lights up blue – The
high beam is switched on.
Malfunction indicator lamp lights up/flashes yellow
– The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized KTM workshop.
The fuel level warning lamp lights up yellow – The
fuel level has reached the reserve mark.
Turn signal indicator lamp flashes green – The turn
signal is switched on.
Ignition lock1is located to the right of the combination instrument.
Possible states
Ignition off – In this position, the ignition circuit
is interrupted, a running engine stops, and a
non-running engine will not start.
Ignition on – In this position, the ignition circuit is
closed and the engine can be started.
6.11 Opening the fuel tank filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
21
Page 24
6 CONTROLS
6.12 Closing the fuel tank filler cap
K01334-10
–
Press release button1, turn the fuel tank filler cap counterclockwise, and lift it off.
–
Mount the fuel tank filler cap and turn it clockwise until
release button1engages.
Info
Route fuel tank breather hose2without kinks.
6.13 Cold start button
K01334-11
The cold start button1is fitted to the bottom of the throttle
valve body.
The electronic fuel injection system extends the injection time if
the engine is cold and the ambient temperature is low. To help the
engine burn the increased fuel quantity, it must be supplied with
additional oxygen by pushing the cold start button.
After briefly opening up the throttle and then releasing the throttle
grip again, or turning the throttle grip towards the front, the cold
start button returns to its original position.
Info
Check whether the cold start button has returned to its
basic position.
Possible states
• The cold start button is activated – The cold start button is
pushed in all the way.
• The cold start button is deactivated – The cold start button is
in its basic position.
H02253-10
22
Page 25
6.14 Idle speed adjusting screw
CONTROLS 6
The idle setting of the throttle valve body substantially influences
the vehicle’s starting behavior, a stable idle speed, and the vehicle’s response when the throttle is opened.
An engine with a correctly set idle speed is easier to start than an
engine with the idle speed set incorrectly.
The idle speed is adjusted using the idle speed adjusting
screw1.
Increase the idle speed by turning the idle speed adjusting screw
clockwise.
Decrease the idle speed by turning the idle speed adjusting screw
counterclockwise.
6.15 Shift lever
H02254-10
Shift lever1is mounted on the left of the engine.
401950-10
The gear positions can be seen in the figure.
The neutral or idle position is between the first and second gears.
401950-11
23
Page 26
6 CONTROLS
6.16 Foot brake lever
6.17 Side stand
Foot brake lever1is located in front of the right footrest.
The rear brake is engaged with the foot brake lever.
401956-10
The side stand1is attached to the left side of the vehicle.
6.18 Steering lock
401943-10
The side stand is used for parking the motorcycle.
Info
When you are riding, side stand1must be folded up and
secured with rubber strap2.
401944-10
Steering lock1is fitted on the left side of the steering head.
The steering lock is used to lock the steering. Steering, and therefore riding, is no longer possible.
S01311-10
24
Page 27
6.19 Locking the steering
Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
– Park the vehicle.
– Turn handlebar as far as possible to the right.
– Lubricate the steering lock regularly.
Universal oil spray ( p. 152)
– Insert the key for the steering lock into the steering lock
( p. 24), turn it to the left, push it in, and turn it to the
right. Pull out the key for the steering lock.
400732-01
Steering is no longer possible.
Info
Never leave the key for the steering lock in the steering
lock.
CONTROLS 6
6.20 Unlocking the steering
400731-01
– Insert the key for the steering lock into the steering lock
( p. 24), turn it to the left, pull it out, and turn it to the
right. Pull out the key for the steering lock.
The handlebar can now be moved again.
Info
Never leave the key for the steering lock in the steering
lock.
25
Page 28
7 COMBINATION INSTRUMENT
7.1 Combination instrument overview
V00799-01
7.2 Activation and test
– Press the button to control different functions.
– Press the button to control different functions.
Info
When the vehicle is delivered, only the SPEED/H and
SPEED/ODO display modes are activated.
Activating combination instrument
The combination instrument is activated when one of the buttons
is pressed or an impulse comes from the wheel speed sensor.
Display test
To enable you to check that the display is functioning properly, all
display segments light up briefly.
400313-01
WS (wheel size)
After the display function check, the wheel circumference WS is
displayed briefly.
Info
The number 2205 equals the circumference of the 21"
front wheel with standard tires.
The display then changes to the last selected mode.
400314-01
7.3 Setting the kilometers or miles
Info
If you change the unit, the value ODO is retained and converted accordingly.
The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed.
Condition
The motorcycle is stationary.
– Repeatedly press the button briefly until H appears at the
bottom right of the display.
– Press the button for 2–3 seconds.
The Setup menu is displayed and the active functions are
shown.
– Repeatedly press the button briefly until Km/h/Mph flashes.
Adjusting the Km/h
– Press the button .
400329-01
Adjusting the Mph
– Press the button .
26
Page 29
COMBINATION INSTRUMENT 7
– Wait 3 - 5 seconds.
The settings are stored.
Info
If no button is pressed for 10–12 seconds, or if an
impulse comes from the wheel speed sensor, the
settings are automatically saved and the setup menu is
closed.
7.4 Setting the combination instrument
Info
When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.
Condition
The motorcycle is stationary.
– Repeatedly press the button briefly until H appears at the
bottom right of the display.
– Press the button for 2–3 seconds.
The Setup menu is displayed and the active functions are
shown.
400318-01
Info
If no button is pressed for 10–12 seconds, the settings
are automatically saved.
If no button is pressed for 20 seconds, or if an impulse
comes from the wheel speed sensor, the settings are
automatically saved and the setup menu is closed.
– Repeatedly press the button briefly until the desired func-
tion flashes.
The selected function flashes.
Activating the function
– Press the button .
The symbol continues to appear in the display and the
next function appears.
Deactivating a function
– Press the button .
The symbol disappears in the display and the next
function appears.
27
Page 30
7 COMBINATION INSTRUMENT
7.5 Setting the clock
400330-01
Condition
The motorcycle is stationary.
– Repeatedly press the button briefly until CLK appears at the
bottom right of the display.
– Press the button for 2–3 seconds.
The hour display flashes.
– Adjust hour display with the button and/or button .
– Wait 3 - 5 seconds.
The next segment of the display flashes and can be set.
– You can set the following segments in the same way as the
hours by pressing the button and the button .
Info
The seconds can only be set to zero.
If no button is pressed for 15-20 seconds, or if an
impulse comes from the wheel speed sensor, the
settings are automatically saved and the setup menu is
closed.
7.6 Viewing the lap time
Info
This function can only be opened if lap times have actually been timed.
Condition
The motorcycle is stationary.
– Repeatedly press the button briefly until LAP appears at the
bottom right of the display.
– Briefly press the button .
LAP 1 appears on the left side of the display.
– The laps 1–10 can be viewed with the button .
– Press and hold the button for 3-5 seconds.
The lap times are deleted.
400321-01
– Briefly press the button .
Next display mode
Info
When an impulse is received from the wheel speed sensor, the left side of the display changes back to the
SPEED mode.
28
Page 31
7.7 Display mode SPEED (speed)
– Repeatedly press the button briefly until SPEED appears on
the left side of the display.
The current speed is displayed in the SPEED display mode.
The current speed can be displayed in Km/h or Mph.
Info
Make the setting according to the country.
When an impulse comes from the front wheel, the left side
400317-02
of the display changes to the SPEED mode and the current
speed is shown.
7.8 Display mode SPEED/H (operating hours)
Condition
• The motorcycle is stationary.
– Repeatedly press the button briefly until H appears at the
bottom right of the display.
In display mode H, the service hours of the engine are displayed.
The service hour counter stores the total traveling time.
COMBINATION INSTRUMENT 7
7.9 Setup menu
400316-01
Info
The service hour counter is necessary for ensuring that
service work is carried out at the right intervals.
If the combination instrument is in H display mode when
starting off, it automatically changes to the ODO display
mode.
The H display mode is suppressed during the journey.
Press the button for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
Condition
• The motorcycle is stationary.
– Repeatedly press the button briefly until H appears at the
bottom right of the display.
– Press the button for 2–3 seconds.
The Setup menu displays the active functions.
The display changes to the functions setup
menu.
Next display mode
No function
No function
400344-01
29
Page 32
7 COMBINATION INSTRUMENT
Info
Repeatedly press the button briefly until the desired
function is reached.
If no button is pressed for 20 seconds, the settings are
automatically saved.
7.10 Setting the unit of measurement
400329-01
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Wait 3 - 5
seconds.
Wait 10 - 12
seconds.
Condition
• The motorcycle is stationary.
– Repeatedly press the button briefly until H appears at the
bottom right of the display.
–
Press the button for 2–3 seconds.
– Repeatedly press the button briefly until Km/h/Mph flashes.
In measurement unit mode, you can change the unit of measurement.
Activates the flashing display and changes to
the next display
No function
Deactivates the flashing display and changes to
the next display
No function
Changes to the next display without changes
Setup menu starts, stores the settings, and
changes to H or ODO.
Info
If no button is pressed for 5 seconds, the settings are automatically saved.
30
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Wait 3 - 5
seconds.
Wait 10 - 12
seconds.
Starts selection, activates Km/h display
No function
Activates Mph display
No function
Changes to the next display, changes from
selection to the Setup menu
Stores and closes the Setup menu
Page 33
7.11 Display mode SPEED/CLK (time)
COMBINATION INSTRUMENT 7
– Repeatedly press the button briefly until CLK appears at the
bottom right of the display.
The time is shown in display mode CLK.
7.12 Setting the clock
400319-01
400319-01
Press the button for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
Condition
• The motorcycle is stationary.
– Repeatedly press the button briefly until CLK appears at the
bottom right of the display.
– Press the button for 2–3 seconds.
Press the button for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
Wait 3 - 5
seconds.
Wait 10 - 12
seconds.
The display changes to the Setup menu of the
clock.
Next display mode
No function
No function
Increases the value
Increases the value
Reduces the value
Reduces the value
Changes to the next value
Closes the SETUP menu
7.13 Display mode SPEED/LAP (lap time)
– Repeatedly press the button briefly until LAP appears at the
In the LAP display mode, up to 10 lap times can be timed with the
stop watch.
400320-01
bottom right of the display.
Info
If the lap time continues running after the button is
pressed, 9 memory locations are occupied.
Lap 10 must be timed using the button .
31
Page 34
7 COMBINATION INSTRUMENT
7.14 Viewing the lap time
400321-01
Press the button for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
Condition
• The motorcycle is stationary.
– Repeatedly press the button briefly until LAP appears at the
bottom right of the display.
– Briefly press the button .
Press the button for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
The stop watch and the lap time are reset.
Next display mode
Stops the clock.
Starts the stop watch or stop the current lap
time measurement, stores it and the stop watch
starts the next lap.
The stop watch and the lap time are reset.
Select a lap from 1–10
No function
View the next lap time.
7.15 Display mode SPEED/ODO (odometer)
– Repeatedly press the button briefly until ODO appears at the
bottom right of the display.
The total traveled distance is shown in display mode ODO.
Press the button for 2–3
seconds.
Briefly press
400317-01
the button .
Press the but-
ton for 2–3
seconds.
Briefly press
the button .
No function
Next display mode
No function
No function
32
Page 35
7.16 Display mode SPEED/TR1 (trip master 1)
– Repeatedly press the button briefly until TR1 appears at the
top right of the display.
TR1 (trip master 1) runs constantly and counts up to 999.9.
You can use it to measure trips or the distance between refueling
stops.
TR1 is coupled with A1 (average speed 1) and S1 (stop watch 1).
Info
400323-01
If 999.9 is exceeded, the values of TR1, A1 and S1 are
automatically reset to 0.0.
COMBINATION INSTRUMENT 7
Press the button for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
7.17 Display mode SPEED/TR2 (trip master 2)
– Repeatedly press the button briefly until TR2 appears at the
top right of the display.
TR2 (trip master 2) runs constantly and counts up to 999.9.
Press the button for 2–3
seconds.
Briefly press
400324-01
the button .
Press the but-
ton for 2–3
seconds.
Briefly press
the button .
Displays of TR1, A1 and S1 are reset to 0,0.
Next display mode
No function
No function
Clears the values TR2 and A2.
Next display mode
Reduces value of TR2.
Reduces value of TR2.
7.18 Setting TR2 (trip master 2)
400324-01
Condition
• The motorcycle is stationary.
– Repeatedly press the button briefly until TR2 appears at the
top right of the display.
– Press the button for 2–3 seconds until TR2 flashes.
The displayed value can be set manually with the button and
the button . This is a very practical function when riding using
the road book.
33
Page 36
7 COMBINATION INSTRUMENT
Info
The TR2 value can also be corrected manually during the
journey with the button and the button .
If 999.9 is exceeded, the value of TR2 is automatically
reset to 0.0.
Press the button for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
Wait 10 - 12
seconds.
7.19 Display mode SPEED/A1 (average speed 1)
–
Repeatedly press the button briefly until A1 appears at the
top right of the display.
A1 (average speed 1) shows the average speed calculated using
TR1 (trip master 1) and S1 (stop watch 1).
The calculation of this value is activated by the first impulse of the
wheel speed sensor and ends 3 seconds after the last impulse.
Press the button for 2–3
400325-01
seconds.
Briefly press
the button .
Press the but-
ton for 2–3
seconds.
Briefly press
the button .
Increases value of TR2.
Increases value of TR2.
Reduces value of TR2.
Reduces value of TR2.
Stores and closes the Setup menu.
Displays of TR1, A1 and S1 are reset to 0.0.
Next display mode
No function
No function
7.20 Display mode SPEED/A2 (average speed 2)
– Repeatedly press the button briefly until A2 appears at the
top right of the display.
A2 (average speed 2) shows the average speed on the basis of the
current speed if the stop watch S2 (stop watch 2) is running.
Info
The displayed value can differ from the actual average
speed if S2 was not stopped after the ride.
400326-01
34
Briefly press
the button .
Next display mode
Page 37
COMBINATION INSTRUMENT 7
Press the button for 2–3
seconds.
Press the button for 2–3
seconds.
Briefly press
the button .
7.21 Display mode SPEED/S1 (stop watch 1)
– Repeatedly press the button briefly until S1 appears at the
top right of the display.
S1 (Stop watch 1) shows the riding time based on TR1 and contin-
ues running as soon as an impulse arrives from the wheel speed
sensor.
The calculation of this value starts with the first impulse from the
wheel speed sensor and ends 3 seconds after the last impulse.
Press the but-
400327-01
ton for 2–3
seconds.
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
No function
No function
No function
Displays of TR1, A1 and S1 are reset to 0.0.
Next display mode
No function
No function
7.22 Display mode SPEED/S2 (stop watch 2)
– Repeatedly press the button briefly until S2 appears at the
top right of the display.
S2 (Stop watch 2) is a manual stop watch.
If S2 is running in the background, the display S2 flashes.
Press the button for 2–3
seconds.
400328-01
Briefly press
the button .
Press the button for 2–3
seconds.
Briefly press
the button .
The displays of S2 and A2 are set to 0,0.
Next display mode
No function
Starts or stops S2.
35
Page 38
7 COMBINATION INSTRUMENT
7.23 Table of functions
Display Press the but-
ton for 2–3
seconds.
Display mode
SPEED/H (operating hours)
Setup menu No function Activates
Setting the unit
of measurement
Display mode
SPEED/CLK
(time)
Setting the
clock
Display mode
SPEED/LAP (lap
time)
Viewing the lap
time
Display mode
SPEED/ODO
(odometer)
Display mode
SPEED/TR1 (trip
master 1)
Display mode
SPEED/TR2 (trip
master 2)
The display
changes to
the functions
setup menu.
No function Starts selec-
The display
changes to
the Setup
menu of the
clock.
Increases the
value
The stop
watch and
the lap time
are reset.
The stop
watch and
the lap time
are reset.
No function Next display
Displays of
TR1, A1 and
S1 are reset
to 0,0.
Clears the
values TR2
and A2.
Briefly press
the button .
Next display
mode
the flashing
display and
changes to
the next display
tion, activates Km/h
display
Next display
mode
Increases the
value
Next display
mode
Select a lap
from 1–10
mode
Next display
mode
Next display
mode
Press the button for 2–3
seconds.
No function No function
No function Deactivates
No function Activates
No function No function
Reduces the
value
Stops the
clock.
No function View the next
No function No function
No function No function
Reduces
value of TR2.
Briefly press
the button .
the flashing
display and
changes to
the next display
Mph display
Reduces the
value
Starts the
stop watch or
stop the current lap time
measurement, stores
it and the
stop watch
starts the
next lap.
lap time.
Reduces
value of TR2.
Wait 3 - 5
seconds.
Changes to
the next display without
changes
Changes to
the next display, changes
from selection to the
Setup menu
Changes
to the next
value
Wait 10 - 12
seconds.
Setup menu
starts, stores
the settings,
and changes
to H or ODO.
Stores and
closes the
Setup menu
Closes the
SETUP menu
36
Page 39
COMBINATION INSTRUMENT 7
Display Press the but-
ton for 2–3
seconds.
Setting TR2
(trip master 2)
Display mode
SPEED/A1 (average speed 1)
Display mode
SPEED/A2 (average speed 2)
Display mode
SPEED/S1 (stop
watch 1)
Display mode
SPEED/S2 (stop
watch 2)
Increases
value of TR2.
Displays of
TR1, A1 and
S1 are reset
to 0.0.
No function Next display
Displays of
TR1, A1 and
S1 are reset
to 0.0.
The displays
of S2 and
A2 are set to
0,0.
Briefly press
the button .
Increases
value of TR2.
Next display
mode
mode
Next display
mode
Next display
mode
Press the button for 2–3
seconds.
Reduces
value of TR2.
No function No function
No function No function
No function No function
No function Starts or
7.24 Table of conditions and menu activation
Briefly press
the button .
Reduces
value of TR2.
stops S2.
Wait 3 - 5
seconds.
Wait 10 - 12
seconds.
Stores and
closes the
Setup menu.
Display The motorcycle is
stationary.
Display mode SPEED/H (operating hours) •
Setup menu •
Setting the unit of measurement •
Setting the clock •
Display mode SPEED/LAP (lap time) •
Viewing the lap time •
Display mode SPEED/TR1 (trip master 1) •
Display mode SPEED/TR2 (trip master 2) •
Setting TR2 (trip master 2) •
Display mode SPEED/A1 (average speed 1) •
Display mode SPEED/A2 (average speed 2) •
Display mode SPEED/S1 (stop watch 1) •
Display mode SPEED/S2 (stop watch 2) •
Menu can be activated
37
Page 40
8 PREPARING FOR USE
8.1 Advice on preparing for first use
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
– Do not operate the vehicle if you are physically or mentally impaired.
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket
with protectors on all rides.
– Always wear protective clothing that is in good condition and meets the legal regulations.
Warning
Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling charac-
teristic.
Different tire tread patterns can make the vehicle significantly more difficult to control.
– Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.
Warning
Danger of accidents An unadapted riding style impairs the handling characteristic.
– Adapt your riding speed to the road conditions and your riding ability.
Warning
Danger of accidents The vehicle is not designed to carry passengers.
– Do not ride with a passenger.
Warning
Danger of accidents The brake system fails in the event of overheating.
If the foot brake lever is not released, the brake linings drag continuously.
– Take your foot off the foot brake lever when you are not braking.
Warning
Danger of accidents Total weight and axle loads influence the handling characteristic.
– Do not exceed the maximum permissible overall weight or the axle loads.
Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running.
– Protect the vehicle against access by unauthorized persons.
Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.
– Make sure that the pre-sales inspection work has been carried out by an authorized KTM workshop.
You will receive a delivery certificate when the vehicle is handed over.
– Before riding for the first time, read the entire Owner's Manual carefully.
– Get to know the controls.
– Adjust basic position of the clutch lever. ( p. 86)
– Adjust the free travel of the handbrake lever. ( p. 90)
38
Page 41
PREPARING FOR USE 8
– Adjust the basic position of the foot brake lever. ( p. 96)
– Adjust the basic position of the shift lever. ( p. 127)
– Get used to the handling characteristics of the motorcycle on a suitable surface before undertaking more chal-
lenging trips.
Info
When offroad, it is recommended that you are accompanied by another person on another vehicle so
that you can help each other.
– Try also to ride as slowly as possible and in a standing position to get a better feel for the motorcycle.
– Do not make any off-road trips that exceed your ability and experience.
– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
– If you carry any luggage, make sure you fix it firmly as close as possible to the center of the vehicle and
ensure even weight distribution between the front and rear wheels.
Info
Motorcycles react sensitively to any changes of weight distribution.
– Do not exceed the maximum permissible weight and maximum permissible axle loads.
Guideline
Maximum permissible overall weight 335 kg (739 lb.)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
– Check the spoke tension. ( p. 106)
Info
The spoke tension must be checked after half an hour of operation.
– Run in the engine. ( p. 39)
8.2 Running-in the engine
– During the running-in phase, do not exceed the specified engine speed and engine performance.
Guideline
Maximum engine speed
During the first operating hour 7,000 rpm
Maximum engine performance
During the first 3 operating hours ≤ 75 %
– Avoid fully opening the throttle!
39
Page 42
8 PREPARING FOR USE
8.3 Starting power of lithium-ion batteries at low temperatures
8.4 Preparing the vehicle for difficult operating conditions
Info
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can result in
significantly increased wear of components, such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.
402555-01
Lithium-ion batteries are far lighter than lead batteries, have a low
self-discharge rate, and have more starting power at temperatures
over 15 °C (60 °F). At low temperatures, however, the starting
power of lithium-ion batteries drops to below that of lead batteries.
Multiple starting attempts may be needed. Press the start button
for 5 seconds, and wait 30 seconds between attempts. The pauses
are necessary so that the heat created can distribute through the
lithium-ion battery and the 12-V battery is not damaged.
If the charged lithium-ion battery is unable to actuate the electric
starter when temperatures are below 15 °C (60 °F), the battery is
not faulty, but needs to be warmed up internally to increase its
starting power (current output).
The starting power increases as the battery warms up.
– Clean the air filter and air filter box. ( p. 73)
Info
Check the air filter approx. every 30 minutes.
– Check the connector for humidity and corrosion and to ensure it is firmly seated.
» If humidity, corrosion, or damage is found:
– Clean and dry the connector, or change it if necessary.
Difficult operating conditions are:
– Rides on dry sand. ( p. 40)
– Rides on wet sand. ( p. 41)
– Rides on wet and muddy circuits. ( p. 42)
– Rides at high temperatures or slow riding. ( p. 42)
– Riding at low temperatures and in snow. ( p. 42)
8.5 Preparing the vehicle for riding on dry sand
– Mount the air filter dust cover.
Air filter dust cover (79006920000)
Info
Observe the fitting instructions for KTM PowerParts.
40
102136-01
Page 43
102138-01
600868-01
PREPARING FOR USE 8
– Mount the air filter sand cover.
Air filter sand cover (79006922000)
Info
Observe the fitting instructions for KTM PowerParts.
–
Clean the chain.
Chain cleaner ( p. 151)
– Mount the steel sprocket.
– Grease the chain.
Universal oil spray ( p. 152)
– Clean the radiator fins.
– Straighten the bent radiator fins carefully.
8.6 Preparing the vehicle for riding on wet sand
– Mount the air filter rain cover.
Air filter rain cover (79006921000)
Info
Observe the fitting instructions for KTM PowerParts.
102137-01
– Clean the chain.
Chain cleaner ( p. 151)
– Mount the steel sprocket.
– Grease the chain.
Universal oil spray ( p. 152)
– Clean the radiator fins.
600868-01
– Straighten the bent radiator fins carefully.
41
Page 44
8 PREPARING FOR USE
8.7 Preparing the vehicle for riding on wet and muddy circuits
– Mount the air filter rain cover.
Air filter rain cover (79006921000)
Info
Observe the fitting instructions for KTM PowerParts.
102137-01
– Mount the steel sprocket.
– Clean the motorcycle. ( p. 133)
– Straighten the bent radiator fins carefully.
600868-01
8.8 Preparing vehicle for high temperatures or slow riding
– Adjust the secondary drive to the road conditions.
Info
The engine oil heats up quickly when the clutch is
operated frequently due to an excessively high secondary ratio.
– Clean the chain.
600868-01
Chain cleaner ( p. 151)
– Clean the radiator fins.
– Straighten the bent radiator fins carefully.
– Check the coolant level. ( p. 120)
8.9 Preparing the vehicle for low temperatures or snow
– Mount the air filter rain cover.
Air filter rain cover (79006921000)
42
Info
Observe the fitting instructions for KTM PowerParts.
102137-01
Page 45
9.1 Checks and maintenance measures when preparing for use
Info
Before every trip, check the condition of the vehicle and ensure that it is safe to operate.
The vehicle must be in perfect technical condition when it is being operated.
– Check the engine oil level. ( p. 129)
– Check the electrical system.
–
Check front brake fluid level. ( p. 91)
– Check the rear brake fluid level. ( p. 96)
– Check the front brake linings. ( p. 93)
– Check the rear brake linings. ( p. 98)
– Check that the brake system is functioning properly.
H02217-01
– Check the coolant level. ( p. 120)
– Check for chain dirt accumulation. ( p. 79)
– Check the chain, rear sprocket, engine sprocket, and chain
guide. ( p. 82)
– Check the chain tension. ( p. 80)
– Check tire condition. ( p. 105)
– Check tire pressure. ( p. 105)
– Check the spoke tension. ( p. 106)
RIDING INSTRUCTIONS 9
Info
The spoke tension must be checked regularly as incorrect spoke tension will strongly impair riding safety.
– Clean the dust boots of the fork legs. ( p. 61)
– Bleed the fork legs. ( p. 60)
– Check the air filter.
– Check the settings of all controls and ensure that they can be
operated smoothly.
–
Check all screws, nuts, and hose clamps regularly for tight-
ness.
– Check the fuel level.
9.2 Starting the vehicle
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
Note
Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.
– Always run the engine warm at a low speed.
43
Page 46
9 RIDING INSTRUCTIONS
401944-10
400733-01
–
Take the motorcycle off side stand1and secure the side
stand with rubber strap2.
– Shift the transmission into neutral.
– Turn the ignition key in the ignition lock to the position .
–
Turn the emergency OFF switch to the position .
Condition
Ambient temperature: < 20 °C (< 68 °F)
– Push the cold start button in all the way.
–
Press the start button.
Info
Press the start button for a maximum of 5 seconds.
Wait for 30 seconds before a further attempt at starting.
At temperatures below 15 °C (60 °F), several attempts
at starting may be necessary to warm-up the lithium-ion
battery and thereby increase the starting power.
During the starting process, the malfunction indicator
lamp lights up.
9.3 Starting off
Info
When you are riding, the side stand must be folded up and secured with the rubber strap.
– Pull the clutch lever, shift into first gear, release the clutch lever slowly and at the same time open the throt-
tle carefully.
9.4 Shifting, riding
Warning
Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine
races.
– Do not change into a low gear at high engine speed.
Info
If unusual noises occur while riding, stop immediately, switch off the engine and contact an authorized
KTM workshop.
First-gear is used for starting off and for steep inclines.
– Shift into a higher gear when conditions allow (incline, road situation, etc.). To do so, release the throttle
while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever and open the
throttle.
– After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This
will barely reduce the speed, but fuel consumption will be considerably lower.
– Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel con-
sumption.
– To shift down, apply the brakes and close the throttle at the same time.
44
Page 47
RIDING INSTRUCTIONS 9
– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and either open the throttle or
shift again.
– Switch off the engine if running at idle speed or stationary for a long time.
Guideline
≥ 2 min
– Avoid frequent and lengthy slipping of the clutch. This causes the engine oil, engine and cooling system to
heat up.
– Ride at a low engine speed instead of at a high engine speed with a slipping clutch.
9.5 Braking
Warning
Danger of accidents Excessively forceful application of the brakes blocks the wheels.
– Adjust application of the brakes to the respective riding situation and riding surface conditions.
Warning
Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
Warning
Danger of accidents Moisture and dirt impair the brake system.
– Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs.
– 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.
– Make use of the braking effect of the engine when driving down long downhill stretches. To do so, shift back
one or two gears, but do not overrev the engine. You will need to apply the brakes far less often and the brake
system will not overheat.
9.6 Stopping, parking
Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running.
– Protect the vehicle against access by unauthorized persons.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system
before the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
– Do not park the vehicle near to materials which are highly flammable or explosive.
– Allow the vehicle to cool down before covering it.
45
Page 48
9 RIDING INSTRUCTIONS
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
– Park the vehicle on a firm and level surface.
– Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
– Apply the brakes on the motorcycle.
– Shift the transmission into neutral.
– Turn the ignition key in the ignition lock to the position while the engine is idling.
– Park the motorcycle on firm ground.
9.7 Transporting
Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
– Do not park the vehicle near to materials which are highly flammable or explosive.
– Allow the vehicle to cool down before covering it.
– Switch off the engine.
– Use tension belts or other suitable devices to secure the
motorcycle against falling over or rolling away.
401475-01
9.8 Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
46
Page 49
RIDING INSTRUCTIONS 9
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
Note
Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged.
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in
problems with the fuel system.
– Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to
help.)
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
401226-10
– Switch off the engine.
– Open the fuel tank filler cap. ( p. 21)
–
Fill the fuel tank with fuel up to a maximum of levelA.
Guideline
Dimension
Total fuel tank
capacity, approx.
– Close the fuel tank filler cap. ( p. 22)
A
35 mm (1.38 in)
8.5 l
(2.25 US gal)
Super unleaded
(ROZ 95/RON
95/PON 91)
( p. 150)
47
Page 50
10 SERVICE SCHEDULE
10.1 Additional information
Any further work that results from the compulsory work or from the recommended work must be ordered separately and invoiced separately.
Different service intervals may apply in your country, depending on the local operating conditions.
Individual service intervals and scopes may change in the course of technical developments. The most up-to-date
service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise
you.
10.2 Required work
Read out the fault memory using the KTM diagnostics tool. ○ ● ● ●
Check that the electrical system is functioning properly. ○ ● ● ●
Check and charge the battery. ● ● ●
Check the front brake linings. ( p. 93) ● ● ●
Check the rear brake linings. ( p. 98) ● ● ●
Check the brake discs. ( p. 90) ● ● ●
Check the brake lines for damage and leakage. ● ● ●
Check the rear brake fluid level. ( p. 96) ● ● ●
Check the free travel of the foot brake lever. ( p. 95) ● ● ●
Check the frame. ( p. 85) ● ● ●
Check the link fork. ( p. 85) ● ● ●
Check the fork bearing for play. ●
Checking the shock absorber heim joint for play. ● ● ●
Check tire condition. ( p. 105) ○ ● ● ●
Check tire pressure. ( p. 105) ○ ● ● ●
Check the wheel bearing for play. ● ● ●
Check the wheel hubs. ● ● ●
Check the rim run-out. ○ ● ● ●
Check the spoke tension. ( p. 106) ○ ● ● ●
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 82) ● ● ●
Check the chain tension. ( p. 80) ○ ● ● ●
Grease all moving parts (e.g. side stand, hand lever, chain, etc.) and check for smooth opera-
tion.
Check/correct the fluid level of the hydraulic clutch. ( p. 87) ● ● ●
Check front brake fluid level. ( p. 91) ● ● ●
Check the free travel of the hand brake lever. ( p. 90) ● ● ●
Check the steering head bearing play. ( p. 66) ○ ● ● ●
Check the valve clearance. ○ ●
Check the clutch. ●
Change the cover seal and shaft seal rings of the water pump. ●
Change the engine oil and oil filter, clean the oil screen. ( p. 129) ○ ● ● ●
Check all hoses (e.g. fuel, cooling, bleeder, drainage hoses, etc.) and sleeves for cracking,
tightness, and correct routing.
every 2,250 km (1,395 mi)
every 1,500 km (930 mi)
every 750 km (465 mi)
after 50 km (31 mi)
● ● ●
○ ● ● ●
48
Page 51
SERVICE SCHEDULE 10
every 2,250 km (1,395 mi)
every 1,500 km (930 mi)
every 750 km (465 mi)
after 50 km (31 mi)
Check the antifreeze and coolant level. ( p. 119) ○ ● ● ●
Check the cables for damage and for routing without kinks. ● ● ●
Check that the throttle cables are undamaged, routed without kinks, and set correctly. ○ ● ● ●
Clean the air filter and air filter box. ( p. 73) ● ● ●
Change the glass fiber yarn filling of the main silencer. ( p. 76) ●
Service the fork. ●
Perform the shock absorber service. ●
Check the tightness of the easily accessible, safety-relevant screws and nuts. ○ ● ● ●
Check the headlight setting. ( p. 115) ○ ● ● ●
Change the fuel screen. ( p. 128) ○ ● ● ●
Check the fuel pressure. ● ● ●
Check idle. ○ ● ● ●
Check that the radiator fan is functioning properly. ○ ● ● ●
Check the inlet membrane. ●
Final check: Check the vehicle is roadworthy and take a test ride. ○ ● ● ●
Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ●
Make a service entry in KTM Dealer.net. ○ ● ● ●
○ One-time interval
● Periodic interval
10.3 Recommended work
every 48 months
every 12 months
every 6,750 km (4,185 mi)
after 1,000 km (620 mi)
after 500 km (310 mi)
Change the front brake fluid. ● ●
Change the rear brake fluid. ● ●
Change the hydraulic clutch fluid. ( p. 88) ● ●
Lubricate the steering head bearing. ( p. 67) ● ●
Clean the spark arrestor. ● ●
Service the fork. ○
Perform the shock absorber service. ○
Change the fuel filter. ●
Change the coolant. ( p. 122) ●
49
Page 52
10 SERVICE SCHEDULE
Perform engine service including removing and installing the engine. (Change the spark
plug and spark plug connector. Change the piston. Check/measure the cylinder. Check
the cylinder head. Change the valves, valve springs, and valve spring seats. Check the
camshaft and cam lever. Change the connecting rod, conrod bearing and crank pin.
Change the shaft seal rings of the water pump. Check the transmission and the shift
mechanism. Check the oil pressure regulator valve. Change the suction pump. Check
the force pump and lubrication system. Check the timing assembly. Change the timing
chain. Change all engine bearings. Change the freewheel.)
○ One-time interval
● Periodic interval
every 48 months
every 12 months
every 6,750 km (4,185 mi)
after 1,000 km (620 mi)
after 500 km (310 mi)
●
50
Page 53
11.1 Checking the basic chassis setting with rider's weight
Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
– For optimal motorcycle riding characteristics and to avoid
damage to forks, shock absorbers, link fork and frame, the
basic settings of the suspension components must match the
rider's weight.
– As delivered, KTM offroad motorcycles are adjusted for an
average rider's weight (with full protective clothing).
Guideline
Standard rider weight 75 … 85 kg (165 …
– If the rider's weight is above or below this range, the basic set-
ting of the suspension components must be adjusted accord-
ingly.
– Small weight differences can be compensated by adjusting the
spring preload, but in the case of large weight differences, the
springs must be replaced.
TUNING THE CHASSIS 11
187 lb.)
401030-01
11.2 Compression damping of the shock absorber
The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.
High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle
speed.
The high-speed compression adjuster has an effect, for example, when landing after a jump: the rear wheel suspension compresses quickly.
The low-speed compression adjuster has an effect, for example, when riding over long ground swells: the rear
wheel suspension compresses slowly.
These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, modifications in the high-speed range affect the compression damping in the low-speed range and vice
versa.
11.3 Adjusting the low-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
–
Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
Info
The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock
absorber.
51
Page 54
11 TUNING THE CHASSIS
V01809-10
–
Turn adjusting screw1clockwise with a screwdriver as far as
the last perceptible click.
Info
Do not loosen fitting2!
– Turn counterclockwise by the number of clicks corresponding
to the shock absorber type.
Guideline
Low-speed compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping during compression.
11.4 Adjusting the high-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
Info
The effect of the high-speed compression adjuster can be seen in fast compression of the shock absorber.
–
Using an open end wrench, turn adjusting screw1clockwise
all the way.
Info
Do not loosen fitting2!
– Turn counterclockwise by the number of turns corresponding
to the shock absorber type.
V01810-10
Guideline
High-speed compression damping
Comfort 2.5 turns
Standard 2 turns
Sport 1 turn
52
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping during compression.
Page 55
TUNING THE CHASSIS 11
11.5 Adjusting the rebound damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
–
Turn adjusting screw1clockwise up to the last perceptible
click.
– Turn counterclockwise by the number of clicks corresponding
to the shock absorber type.
Guideline
Rebound damping
Comfort 18 clicks
S01314-10
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber
rebounds.
11.6 Measuring the dimension of the rear wheel unloaded
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 60)
Main work
– Position the sag gage in the rear axle and measure the
distance to marking SAG on the rear fender.
Sag gauge (00029090100)
Sag gage pin (00029990010)
–
Note the value as dimensionA.
402415-10
Finishing work
– Remove the motorcycle from the lift stand. ( p. 60)
53
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11 TUNING THE CHASSIS
11.7 Checking the static sag of the shock absorber
–
Measure dimensionAof rear wheel unloaded. ( p. 53)
– Hold the motorcycle upright with aid of an assistant.
– Measure the distance again between the rear axle and mark-
ing SAG on the rear fender using the sag gage.
–
Note the value as dimensionB.
Info
The static sag is the difference between
measurementsAandB.
– Check the static sag.
Static sag 37 mm (1.46 in)
» If the static sag is less or more than the specified value:
– Adjust the spring preload of the shock absorber.
( p. 55)
402416-10
11.8 Checking the riding sag of the shock absorber
–
Measure dimensionAof rear wheel unloaded. ( p. 53)
– With another person holding the motorcycle, the rider, wear-
ing full protective clothing, sits on the seat in a normal sitting
position (feet on footrests) and bounces up and down a few
times.
The rear wheel suspension levels out.
– Another person again measures the distance between the rear
axle and marking SAG on the rear fender using the sag gage.
–
Note the value as dimensionC.
Info
The riding sag is the difference between
measurementsAandC.
– Check riding sag.
Riding sag 110 mm (4.33 in)
» If the riding sag differs from the specified measurement:
402417-10
– Adjust the riding sag. ( p. 56)
54
Page 57
TUNING THE CHASSIS 11
11.9 Adjusting the spring preload of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
Info
Before changing the spring preload, make a note of the present setting, e.g., by measuring the spring
length.
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 60)
– Remove the shock absorber. ( p. 69)
– After removing the shock absorber, clean it thoroughly.
Main work
–
Loosen screw1.
–
Turn adjusting ring2until the spring is no longer under ten-
sion.
402659-10
Hook wrench (90129051000)
Info
If the spring cannot be fully released, the spring must
be removed to accurately measure the spring length.
– Measure the total spring length while the spring is not under
tension.
–
Tension the spring by turning adjusting ring2to specified
dimensionA.
Guideline
Spring preload 8 mm (0.31 in)
Info
Depending on the static sag and/or the riding sag, it
may be necessary to increase or decrease the spring
preload.
–
Tighten screw1.
Guideline
Screw, shock
absorber adjusting
ring
M5 5 Nm (3.7 lbf ft)
Finishing work
– Install the shock absorber. ( p. 69)
– Remove the motorcycle from the lift stand. ( p. 60)
55
Page 58
11 TUNING THE CHASSIS
11.10 Adjusting the riding sag
B00292-10
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 60)
– Remove the shock absorber. ( p. 69)
– After removing the shock absorber, clean it thoroughly.
Main work
– Choose and mount a suitable spring.
Guideline
Spring rate
Weight of rider: 65 …
75 kg (143 … 165 lb.)
Weight of rider: 75 …
85 kg (165 … 187 lb.)
Weight of rider: 85 …
95 kg (187 … 209 lb.)
60 … 66 N/mm (343 …
377 lb/in)
63 … 69 N/mm (360 …
394 lb/in)
66 … 72 N/mm (377 …
411 lb/in)
Info
The spring rate is shown on the outside of the spring.
Smaller weight differences can be compensated by
changing the spring preload.
Finishing work
– Install the shock absorber. ( p. 69)
–
Remove the motorcycle from the lift stand. ( p. 60)
– Check the static sag of the shock absorber. ( p. 54)
– Check the riding sag of the shock absorber. ( p. 54)
– Adjust the rebound damping of the shock absorber. ( p. 53)
11.11 Checking the basic setting of the fork
Info
For various reasons, no exact riding sag can be determined for the fork.
– As with the shock absorber, smaller differences in the rider's
weight can be compensated by the spring preload.
– However, if the fork frequently bottoms out (hard end stop on
compression), harder springs must be fitted to avoid damage
to the fork and frame.
– If the fork feels unusually hard after extended periods of oper-
ation, the fork legs need to be bled.
401000-01
56
Page 59
11.12 Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
–
Turn white adjuster1clockwise as far as it will go.
Info
Adjuster1is located at the upper end of the left fork
leg.
The compression damping is located in left fork
leg COMP (white adjuster). The rebound damping is
located in right fork leg REB (red adjuster).
TUNING THE CHASSIS 11
S03470-10
– Turn counterclockwise by the number of clicks corresponding
to the fork type.
Guideline
Compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping during compression.
11.13 Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
–
Turn red adjuster1clockwise as far as it will go.
Info
Adjuster1is located at the upper end of the right
fork leg.
The rebound damping is located in right fork leg REB
(red adjuster). The compression damping is located in
left fork leg COMP (white adjuster).
V01754-10
– Turn counterclockwise by the number of clicks corresponding
to the fork type.
Guideline
Rebound damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
57
Page 60
11 TUNING THE CHASSIS
11.14 Handlebar position
Info
Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber
rebounds.
On the upper triple clamp, there are 2 holes at a distance ofAto
each other.
15 mm (0.59 in)
3.5 mm (0.138 in)
M00993-10
Hole distance
The holes on the handlebar supports are placed at a distance
ofBfrom the center.
Hole distance
The handlebar holders can be mounted in four different positions.
A
B
11.15 Adjusting the handlebar position
Warning
Danger of accidents A repaired handlebar poses a safety risk.
If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a
result.
– Change the handlebar if the handlebar is damaged or bent.
58
Page 61
TUNING THE CHASSIS 11
–
Remove screws1. Take off the handlebar clamps. Remove
the handlebar and lay it to one side.
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
–
Remove screws2. Take off the handlebar supports.
– Place the handlebar supports in the required position. Mount
and tighten screws2.
Guideline
Screw, handlebar holder
Info
Position the left and right handlebar supports evenly.
– Position the handlebar.
M10 40 Nm (29.5 lbf ft)
Loctite®243™
M00993-11
Info
Make sure the cables and wiring are positioned correctly.
–
Position the handlebar clamps. Mount screws1and tighten
evenly.
Guideline
Screw, handlebar
clamp
M8 20 Nm (14.8 lbf ft)
Info
Make sure the gap widths are even.
59
Page 62
12 SERVICE WORK ON THE CHASSIS
12.1 Raising the motorcycle with the lift stand
Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
– Raise the motorcycle at the frame underneath the engine.
– Secure the motorcycle against falling over.
401942-01
12.2 Removing the motorcycle from the lift stand
Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
Lift stand (78129955100)
Neither wheel is in contact with the ground.
401943-10
12.3 Bleeding the fork legs
402556-10
– Remove the motorcycle from the lift stand.
– Remove the lift stand.
–
To park the motorcycle, press side stand1to the ground
with your foot and lean the motorcycle on it.
Info
When you are riding, the side stand must be folded up
and secured with rubber strap.
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 60)
Main work
–
Release bleeder screws1.
Any excess pressure escapes from the interior of the fork.
– Tighten the bleeder screws.
60
Finishing work
– Remove the motorcycle from the lift stand. ( p. 60)
Page 63
12.4 Cleaning the dust boots of the fork legs
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 60)
– Remove the fork protector. ( p. 61)
Main work
–
Push dust boots1of both fork legs downward.
K00070-10
SERVICE WORK ON THE CHASSIS 12
Info
The dust boots remove dust and coarse dirt particles
from the inside fork tubes. Over time, dirt can accumulate behind the dust boots. If this dirt is not removed,
the oil seals behind can start to leak.
Warning
Danger of accidents Oil or grease on the brake discs
reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when nec-
essary.
12.5 Removing the fork protector
V00332-10
– Clean and oil the dust boots and inner fork tubes of both fork
legs.
Universal oil spray ( p. 152)
– Press the dust boots back into their installation position.
– Remove excess oil.
Finishing work
– Install the fork protector. ( p. 62)
– Remove the motorcycle from the lift stand. ( p. 60)
–
Remove screws1and take off the clamp.
–
Remove screws2on the left fork leg and take off the left
fork protector.
–
Remove screws3on the right fork leg and take off the right
fork protector.
61
Page 64
12 SERVICE WORK ON THE CHASSIS
12.6 Installing the fork protector
– Position the fork protector on the left fork leg. Mount and
– Position the brake line, wiring harness, and clamp. Mount and
– Position the fork protector on the right fork leg. Mount and
V00332-11
12.7 Removing the fork legs
Preparatory work
– Turn the ignition key in the ignition lock to the position
– Remove the headlight mask with the headlight. ( p. 113)
– Raise the motorcycle with the lift stand. ( p. 60)
– Remove the front wheel. ( p. 101)
Main work
–
– Remove the cable ties.
–
– Hang the brake caliper and the brake line loosely to the side.
tighten screws1.
Guideline
Remaining screws,
chassis
tighten screws2.
tighten screws3.
Guideline
Remaining screws,
chassis
while the engine is idling.
Remove screws1and take off the clamp.
Remove screws2and take off the brake caliper.
M6 10 Nm (7.4 lbf ft)
M6 10 Nm (7.4 lbf ft)
K00545-10
V01756-10
–
Loosen screws3. Take out the left fork leg.
–
Loosen screws4. Take out the right fork leg.
62
Page 65
12.8 Installing the fork legs
402556-10
V01756-11
SERVICE WORK ON THE CHASSIS 12
Main work
– Position the fork legs.
Bleeder screws1are positioned toward the front.
Info
Grooves are milled into the side of the upper end of the
fork legs. The second milled groove (from the top) must
be flush with the upper edge of the upper triple clamp.
–
Tighten screws2.
Guideline
Screw, top triple
clamp
–
Tighten screws3.
Guideline
Screw, bottom triple
clamp
M8 20 Nm (14.8 lbf ft)
M8 15 Nm (11.1 lbf ft)
K00546-10
12.9 Removing the lower triple clamp
–
Position the brake caliper, and mount and tighten screws4.
Guideline
Screw, front
brake caliper
– Mount the cable ties.
– Position the brake line, the wiring harness, and the clamp.
Mount and tighten screws5.
Finishing work
– Install the front wheel. ( p. 102)
– Install the headlight mask with the headlight. ( p. 114)
– Check the headlight setting. ( p. 115)
Preparatory work
– Turn the ignition key in the ignition lock to the position
while the engine is idling.
– Remove the headlight mask with the headlight. ( p. 113)
– Raise the motorcycle with the lift stand. ( p. 60)
– Remove the front wheel. ( p. 101)
– Remove the fork legs. ( p. 62)
– Remove front fender. ( p. 68)
– Remove the handlebar cushion.
M8 25 Nm (18.4 lbf ft)
Loctite®243™
63
Page 66
12 SERVICE WORK ON THE CHASSIS
Main work
– Open the cable holder in front of the left radiator and detach
–
–
– Take off the upper triple clamp with the handlebar and set it
the wiring harness.
Loosen screw1.
Remove screw2.
aside.
V01785-10
V01757-10
12.10 Installing the lower triple clamp
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
–
Remove O-ring3and protective ring4.
– Take off the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.
Main work
– Clean the bearing and sealing elements, check for damage,
and grease.
High viscosity grease ( p. 151)
– Insert the lower triple clamp with the steering stem. Mount
upper steering head bearing.
–
Check whether upper steering head seal1is correctly positioned.
–
Slide on protective ring2and O-ring3.
64
B01605-10
Page 67
V01785-11
V01791-10
SERVICE WORK ON THE CHASSIS 12
– Position the upper triple clamp with the handlebar.
–
Mount screw4but do not tighten yet.
– Secure the wiring harness and the clutch line with the cable
holder.
–
Position the fork legs.
Bleeder screws5are positioned toward the front.
Info
The rebound damping is located in right fork leg REB
(red adjuster).
The compression damping is located in left fork
leg COMP (white adjuster).
Grooves are milled into the side of the upper end of the
fork legs. The second milled groove (from the top) must
be flush with the upper edge of the upper triple clamp.
V01790-10
V01789-10
–
Tighten screws6.
Guideline
Screw, bottom triple
clamp
–
Tighten screw4.
Guideline
Screw, top steering
head
–
Tighten screw7.
Guideline
Screw, top steering
stem
–
Tighten screws8.
Guideline
Screw, top triple
clamp
M8 15 Nm (11.1 lbf ft)
M20x1.5 12 Nm (8.9 lbf ft)
M8 20 Nm (14.8 lbf ft)
M8 20 Nm (14.8 lbf ft)
V01790-11
65
Page 68
12 SERVICE WORK ON THE CHASSIS
–
– Mount the cable ties.
– Position the brake line, the wiring harness, and the clamp.
V01792-10
Finishing work
– Mount the handlebar cushion.
– Install front fender. ( p. 68)
– Install the front wheel. ( p. 102)
– Install the headlight mask with the headlight. ( p. 114)
– Check that the wiring harness, throttle cables, and brake and
– Check the steering head bearing play. ( p. 66)
– Remove the motorcycle from the lift stand. ( p. 60)
– Check the headlight setting. ( p. 115)
Position the brake caliper, and mount and tighten screws9.
Guideline
Screw, front
brake caliper
Mount and tighten screwsbk.
clutch lines can move freely and are routed correctly.
M8 25 Nm (18.4 lbf ft)
Loctite®243™
12.11 Checking the steering head bearing play
Warning
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam-
ages components.
– Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad
to help.)
Info
If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the
bearing seats in the frame can become damaged over time.
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 60)
Main work
– Move the handlebar to the straight-ahead position. Move the
fork legs to and fro in the direction of travel.
Play should not be detectable on the steering head bearing.
» If there is detectable play:
– Adjust the steering head bearing play. ( p. 67)
– Move the handlebar to and fro over the entire steering range.
66
H01167-01
It must be possible to move the handlebar easily over the
entire steering range. There should be no detectable detent
positions.
» If detent positions are detected:
– Adjust the steering head bearing play. ( p. 67)
Page 69
– Check the steering head bearing and replace if neces-
Finishing work
– Remove the motorcycle from the lift stand. ( p. 60)
12.12 Adjusting the steering head bearing play
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 60)
Main work
–
Loosen screws1and2.
–
Loosen and retighten screw3.
Guideline
Screw, top steering
head
– Using a plastic hammer, tap lightly on the upper triple clamp
K01336-10
to avoid stresses.
–
Tighten screws1.
Guideline
Screw, top triple
clamp
SERVICE WORK ON THE CHASSIS 12
sary.
M20x1.5 12 Nm (8.9 lbf ft)
M8 20 Nm (14.8 lbf ft)
–
Tighten screw2.
Guideline
Screw, top steering
stem
Finishing work
– Check the steering head bearing play. ( p. 66)
– Remove the motorcycle from the lift stand. ( p. 60)
12.13 Lubricating the steering head bearing
– Remove the lower triple clamp. ( p. 63)
– Install the lower triple clamp. ( p. 64)
H02387-01
M8 20 Nm (14.8 lbf ft)
67
Page 70
12 SERVICE WORK ON THE CHASSIS
12.14 Removing front fender
Preparatory work
– Turn the ignition key in the ignition lock to the position
– Remove the headlight mask with the headlight. ( p. 113)
Main work
–
V00340-10
–
while the engine is idling.
Remove screws1.
Remove screws2. Remove front fender.
12.15 Installing front fender
V00341-10
V00340-10
V00341-10
Main work
–
Position front fender. Mount and tighten screws1.
Guideline
Remaining screws,
chassis
–
Mount and tighten screws2.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
M6 10 Nm (7.4 lbf ft)
68
Finishing work
– Install the headlight mask with the headlight. ( p. 114)
– Check the headlight setting. ( p. 115)
Page 71
12.16 Removing the shock absorber
V01811-10
12.17 Installing the shock absorber
SERVICE WORK ON THE CHASSIS 12
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 60)
Main work
–
Remove screw1and lower the rear wheel with the link fork
as far as possible without blocking the rear wheel. Secure the
rear wheel in this position.
–
Remove screw2, push splash protector3to the side, and
remove the shock absorber.
Main work
–
Push splash protector1to the side and position the shock
absorber. Mount and tighten screw2.
Guideline
Screw, top
shock absorber
M12 80 Nm (59 lbf ft)
Loctite®2701™
12.18 Removing the seat
V01811-11
–
Mount and tighten screw3.
Guideline
Screw, bottom
shock absorber
M12 80 Nm (59 lbf ft)
Loctite®2701™
Info
The heim joint for the shock absorber on the link fork
is Teflon coated. It must not be lubricated with grease,
nor with any other lubricants. Lubricants dissolve the
Teflon coating, thereby drastically reducing the service
life.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 60)
–
Remove screw1.
S03480-10
69
Page 72
12 SERVICE WORK ON THE CHASSIS
– Raise the rear of the seat, pull the seat back, and lift it off.
H02218-10
12.19 Mounting the seat
–
– Make sure the seat is locked in correctly.
Mount the front of the seat on the collar bushings of the fuel
tank, lower the seat at the rear, and push the seat forward.
H02218-11
–
S03480-10
12.20 Removing the air filter box cover
Condition
Mount and tighten screw1.
Guideline
Remaining screws,
chassis
The air filter box cover is secured.
– Remove the seat. ( p. 69)
–
Remove screw1.
M6 10 Nm (7.4 lbf ft)
70
V01815-10
Page 73
V01815-11
V01816-10
SERVICE WORK ON THE CHASSIS 12
–
Pull off the air filter box cover in areaAlaterally and take
it off at the front.
Condition
The air filter box cover is not secured.
–
Pull off the air filter box cover in areaAlaterally and take
it off at the front.
12.21 Installing the air filter box cover
V01815-12
V01815-10
Condition
The air filter box cover is secured.
–
Insert the air filter box cover in areaAand clip it into
areaB.
–
Mount and tighten screw1.
Guideline
Screw, air filter box
cover
®
EJOT PT
K60x20-Z
– Mount the seat. ( p. 70)
Condition
The air filter box cover is not secured.
–
Insert the air filter box cover in areaAand clip it into
areaB.
3 Nm (2.2 lbf ft)
V01816-11
71
Page 74
12 SERVICE WORK ON THE CHASSIS
12.22 Removing the air filter
Note
Engine damage Unfiltered intake air has a negative effect on the service life of the engine.
Dust and dirt will enter the engine without an air filter.
– Never start to use the vehicle without an air filter.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Preparatory work
– Remove the air filter box cover. ( p. 70)
Main work
–
– Remove air filter from air filter support.
Detach retaining tab1. Remove air filter with air filter support.
12.23 Installing the air filter
H02459-01
V01812-10
V01813-10
Main work
– Mount the clean air filter on the air filter support.
–
Grease the air filter in areaA.
Long-life grease ( p. 151)
–
Insert air filter and position retaining pin1in bushingB.
The air filter is correctly positioned.
–
Secure the bottom retaining pin with holding tab2.
Info
If the air filter is not mounted correctly, dust and dirt
may enter the engine and result in damage.
72
Finishing work
– Install the air filter box cover. ( p. 71)
Page 75
SERVICE WORK ON THE CHASSIS 12
12.24 Cleaning the air filter and air filter box
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.
Preparatory work
– Remove the air filter box cover. ( p. 70)
– Remove the air filter. ( p. 72)
Main work
– Wash the air filter thoroughly in special cleaning liquid and
allow it to dry properly.
Air filter cleaner ( p. 151)
–
A00061-10
Oil the dry air filter with a high-grade air filter oil.
Oil for foam air filter ( p. 151)
– Clean the air filter box.
– Check the intake flange for damage and looseness.
Finishing work
– Install the air filter. ( p. 72)
– Install the air filter box cover. ( p. 71)
12.25 Preparing air filter box cover for securing
Preparatory work
– Remove the air filter box cover. ( p. 70)
Main work
–
Drill a hole at markingA.
Guideline
Diameter 6 mm (0.24 in)
Info
Only press the air filter to dry it, never wring it out.
S03499-10
Finishing work
– Install the air filter box cover. ( p. 71)
73
Page 76
12 SERVICE WORK ON THE CHASSIS
12.26 Removing the main silencer
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.
–
–
V01814-10
12.27 Installing the main silencer
– Position the catalytic converter in the main silencer.
Detach spring1.
Spring hook (50305017000C1)
Remove screws2and take off the main silencer with the
catalytic converter.
S02101-10
–
Position the main silencer. Mount screws1, but do not
tighten yet.
–
Attach spring2.
Spring hook (50305017000C1)
–
Tighten screws1.
Guideline
V01814-11
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
12.28 Cleaning the spark arrestor
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.
Info
Soot particles accumulate on the screen of the spark arrestor over time.
This changes the performance characteristics.
74
Page 77
Preparatory work
– Remove main silencer. ( p. 74)
SERVICE WORK ON THE CHASSIS 12
Main work
–
Remove screws1and take off silencer cap2with O-ring3.
Info
Do not remove the glass fiber yarn filling.
Caution
Danger to health Soot particles irritate the eyes and mucuous membranes.
– Wear suitable breathing and eye protection when cleaning the main silencer and carbon screen.
–
Clean main silencer sleeve4and screen5of the spark arrestor with compressed air.
–
Mount new O-ring3on silencer cap2.
–
Position silencer cap2. Mount and tighten screws1.
Guideline
Screws on main silencer M5 7 Nm (5.2 lbf ft)
Finishing work
– Install the main silencer. ( p. 74)
V01736-10
75
Page 78
12 SERVICE WORK ON THE CHASSIS
12.29 Changing the glass fiber yarn filling of the main silencer
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.
Info
Over time, the fibers of the glass fiber yarn escape and the damper “burns” out.
Not only is the noise level higher, but the performance characteristics change.
Preparatory work
– Remove main silencer. ( p. 74)
Main work
–
–
– Remove the old glass fiber yarn filling.
– Clean the parts that need to be reinstalled and check for dam-
–
– Mount the O-ring on the silencer cap.
– Position the silencer cap.
– Mount and tighten all of the screws.
Remove screws1.
Take off silencer cap2with O-ring3.
age.
Mount the new glass fiber yarn filling4in the main silencer.
Guideline
Screws on main
silencer
M5 7 Nm (5.2 lbf ft)
V01735-10
Finishing work
– Install the main silencer. ( p. 74)
12.30 Removing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
76
Page 79
SERVICE WORK ON THE CHASSIS 12
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
Preparatory work
– Remove the seat. ( p. 69)
Main work
–
Unplug connector1of the fuel pump.
–
Clean plug-in connection2of the fuel line thoroughly with
compressed air.
Info
Under no circumstances should dirt enter into the fuel
line. Dirt in the fuel line clogs the injection valve!
V01824-10
V01825-10
V01764-10
– Disconnect the plug-in connection of the fuel line.
Info
Remaining fuel may flow out of the fuel line.
–
Mount wash cap set3.
Wash cap set (81212016100)
–
Remove screws4.
– Hang the horn and horn bracket to one side.
–
Remove screw5with the rubber bushing.
– Remove the hose from the fuel tank breather.
V01766-10
77
Page 80
12 SERVICE WORK ON THE CHASSIS
– Pull both spoilers laterally off the radiator and lift off the fuel
V01767-10
12.31 Installing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
tank.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
Main work
– Check throttle cable routing. ( p. 85)
– Position the fuel tank and fit the two spoilers to the sides in
front of the radiator bracket.
– Make sure that no cables or throttle cables are trapped or dam-
aged.
V01767-11
78
Page 81
V01766-11
V01764-11
SERVICE WORK ON THE CHASSIS 12
– Attach the fuel tank breather hose.
–
Mount and tighten screw1with the rubber bushing.
Guideline
Remaining screws,
chassis
–
Position the horn with the horn bracket.
–
Mount and tighten screws2.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
M6 10 Nm (7.4 lbf ft)
–
Plug in connector3for the fuel pump.
– Remove the wash cap set.
– Thoroughly clean the plug-in connection of the fuel line using
compressed air.
V01824-11
– Spray silicone spray onto a lint-free cleaning cloth and lightly
lubricate the O-ring of the quick-release coupling.
Silicone spray ( p. 152)
–
Join the plug-in connection4of the fuel line.
Finishing work
– Mount the seat. ( p. 70)
12.32 Checking for chain dirt accumulation
Info
Under no circumstances should dirt enter into the fuel
line. Dirt in the fuel line clogs the injection valve!
Info
Route the cable and fuel line at a safe distance from
the exhaust system.
400678-01
– Check the chain for coarse dirt accumulation.
» If the chain is very dirty:
– Clean the chain. ( p. 80)
79
Page 82
12 SERVICE WORK ON THE CHASSIS
12.33 Cleaning the chain
Warning
Danger of accidents Lubricants on the tires reduces the road grip.
– Remove lubricants from the tires using a suitable cleaning agent.
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
The service life of the chain depends largely on its maintenance.
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 60)
Main work
– Rinse off loose dirt with a soft jet of water.
– Remove old grease residue with chain cleaner.
Chain cleaner ( p. 151)
– After drying, apply chain spray.
Off-road chain spray ( p. 151)
400725-01
Finishing work
– Remove the motorcycle from the lift stand. ( p. 60)
12.34 Checking the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear
wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the
rear wheel locks or the engine will be damaged.
– Check the chain tension regularly.
– Set the chain tension in accordance with the specification.
80
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 60)
Page 83
V00354-10
SERVICE WORK ON THE CHASSIS 12
Main work
– Pull the chain at the end of the chain sliding piece upward to
measure chain tensionA.
Info
Lower chain section1must be taut.
When the chain guard is mounted, it must be possible
to pull up the chain at least to the point where it makes
contact with chain guardB.
Chain wear is not always even, so you should repeat
this measurement at different chain positions.
Chain tension 55 … 58 mm (2.17 …
2.28 in)
» If the chain tension does not meet the specification:
– Adjust the chain tension. ( p. 81)
Finishing work
– Remove the motorcycle from the lift stand. ( p. 60)
12.35 Adjusting the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear
wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the
rear wheel locks or the engine will be damaged.
– Check the chain tension regularly.
– Set the chain tension in accordance with the specification.
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 60)
– Check the chain tension. ( p. 80)
81
Page 84
12 SERVICE WORK ON THE CHASSIS
Main work
–
–
–
–
–
–
E00330-10
Loosen nut1.
Loosen nuts2.
Adjust the chain tension by turning adjusting screws3left
and right.
Guideline
Chain tension 55 … 58 mm (2.17 …
2.28 in)
Turn adjusting screws3on the left and right so that the
markings on the left and right chain adjusters are in the
same position relative to reference marksA. The rear
wheel is then correctly aligned.
Tighten nuts2.
Make sure that chain adjusters4are fitted correctly on
adjusting screws3.
Tighten nut1.
Guideline
Nut, rear wheel spindle
M20x1.5 80 Nm (59 lbf ft)
Info
The wide adjustment range of the chain adjusters
(32 mm (1.26 in)) enables different secondary ratios
with the same chain length.
Chain adjusters4can be turned by 180°.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 60)
12.36 Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work
– Raise the motorcycle with the lift stand. ( p. 60)
Main work
– Shift the transmission into neutral.
– Check the chain, rear sprocket, and engine sprocket for wear.
» If the chain, rear sprocket or engine sprocket is worn:
–
Change the drivetrain kit.
Info
The engine sprocket, rear sprocket, and chain
400227-01
should always be replaced together.
82
Page 85
SERVICE WORK ON THE CHASSIS 12
– Pull on the top section of the chain with the specified
weightA.
Guideline
Weight of chain wear measurement
–
Measure distanceBof 18 chain rollers in the lower chain
section.
Info
Chain wear is not always even, so you should repeat
this measurement at different chain positions.
10 … 15 kg (22 … 33 lb.)
400987-10
Maximum distanceBfrom
18 chain rollers at the
longest chain section
»
If distanceBis greater than the specified measurement:
– Change the drivetrain kit.
272 mm (10.71 in)
Info
When a new chain is mounted, the rear sprocket
and engine sprocket should also be changed.
New chains wear out faster on old, worn sprockets.
– Check the chain sliding guard for wear.
» If the lower edge of the chain pins is in line with, or below,
the chain sliding guard:
– Change the chain sliding guard.
– Check that the chain sliding guard is firmly seated.
» If the chain sliding guard is loose:
– Tighten screws on the chain sliding guard.
Guideline
Screw, chain
sliding guard
M6 10 Nm (7.4 lbf ft)
Loctite®243™
V01829-10
83
Page 86
12 SERVICE WORK ON THE CHASSIS
– Check chain sliding piece for wear.
– Check that the chain sliding piece is firmly seated.
V01830-10
» If the lower edge of the chain pins is in line with or below
the chain sliding piece:
– Change the chain sliding piece.
» If the chain sliding piece is loose:
– Tighten the screw of the chain sliding piece.
Guideline
Screw, chain sliding piece
M8 15 Nm
(11.1 lbf ft)
401760-01
E00333-01
– Check the chain guide for wear.
Info
Wear can be seen on the front of the chain guide.
» If the light part of the chain guide is worn:
– Change the chain guide.
– Check that the chain guide is firmly seated.
» If the chain guide is loose:
– Tighten the screws on the chain guide.
Guideline
Remaining screws,
chassis
Remaining nuts,
chassis
Finishing work
– Remove the motorcycle from the lift stand. ( p. 60)
M6 10 Nm
(7.4 lbf ft)
M6 10 Nm
(7.4 lbf ft)
84
Page 87
12.37 Checking the frame
S01316-10
12.38 Checking the link fork
SERVICE WORK ON THE CHASSIS 12
– Check the frame for cracking and deformation.
» If the frame exhibits cracking or deformation due to a
mechanical impact:
– Change the frame.
Info
Always replace a frame that has been damaged due to a mechanical impact. Repair of the
frame is not authorized by KTM.
– Check the link fork for damage, cracking, and deformation.
» If the link fork exhibits damage, cracking, or deformation:
– Change the link fork.
Info
Always replace a damaged link fork. Repairing
the link fork is not authorized by KTM.
S01317-10
12.39 Checking throttle cable routing
Preparatory work
– Remove the seat. ( p. 69)
– Remove the fuel tank. ( p. 76)
Main work
– Check throttle cable routing.
Both throttle cables must be routed, side by side, on the
back of the handlebars and above the fuel tank bracket, to
the throttle valve body. Both throttle cables must be secured
behind the rubber strap of the fuel tank support.
» If the throttle cable routing is not as specified:
– Correct throttle cable routing.
E00502-01
Finishing work
– Install the fuel tank. ( p. 78)
85
Page 88
12 SERVICE WORK ON THE CHASSIS
– Mount the seat. ( p. 70)
12.40 Checking the rubber grip
– Check the rubber grips on the handlebar for damage, wear,
401197-01
–
and looseness.
Info
The rubber grips are vulcanized onto a sleeve on the
left and onto the handle tube of the throttle grip on the
right. The left sleeve is clamped onto the handlebar.
The rubber grip can only be replaced with the sleeve or
the throttle tube.
» If a rubber grip is damaged, worn, or loose:
– Change the rubber grip.
Check that screw1is firmly seated.
Guideline
Screw, fixed
grip
M4 5 Nm (3.7 lbf ft)
Loctite®243™
DiamondAmust be located at the top.
V00461-10
12.41 Adjusting the basic position of the clutch lever
– Adjust the basic position of the clutch lever to your hand size
by turning adjusting screw1.
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 handle-
E00842-10
bar.
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.
86
Page 89
SERVICE WORK ON THE CHASSIS 12
12.42 Checking/correcting the fluid level of the hydraulic clutch
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
The fluid level rises with increasing wear of the clutch facing discs.
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
– Move the clutch fluid reservoir mounted on the handlebar to a
horizontal position.
–
Remove screws1.
–
Remove cover2with membrane3.
– Check the fluid level.
V00456-10
Fluid level below container
rim
» If the fluid level does not meet specifications:
– Correct the fluid level of the hydraulic clutch.
Brake fluid DOT 4 / DOT 5.1 ( p. 149)
– Position the cover with the membrane. Mount and tighten the
screws.
4 mm (0.16 in)
Info
Clean up overflowed or spilled brake fluid immediately
with water.
87
Page 90
12 SERVICE WORK ON THE CHASSIS
12.43 Changing the hydraulic clutch fluid
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
– Move the hydraulic clutch fluid reservoir mounted on the han-
dlebar into a horizontal position.
–
Remove screws1.
–
Take off cover2with membrane3.
V00456-10
–
Fill bleeding syringe4with the appropriate hydraulic fluid.
Syringe (50329050000)
Brake fluid DOT 4 / DOT 5.1 ( p. 149)
– On the clutch slave cylinder, remove the protection cap,
remove bleeder screw5and mount bleeding syringe4.
88
V01817-10
Page 91
E00339-10
SERVICE WORK ON THE CHASSIS 12
– Now inject fluid into the system until it escapes from the
opening6of the master cylinder without bubbles.
– Occasionally extract the fluid from the master cylinder reser-
voir to prevent overflowing.
– Remove the bleeding syringe. Mount and tighten the bleeder
screw. Mount the protection cap.
– Correct the fluid level of the hydraulic clutch.
Guideline
Fluid level below container
rim
– Position the cover with the membrane. Mount and tighten the
screws.
Info
Immediately clean up any brake fluid that has overflowed or spilled with water.
4 mm (0.16 in)
89
Page 92
13 BRAKE SYSTEM
13.1 Checking the free travel of the hand brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit.
– Set the free travel on the hand brake lever in accordance with the specification.
– Push the hand brake lever to the handlebar and check free
travelA.
Free travel of hand brake
lever
» If the free travel does not match the specification:
– Adjust the free travel of the handbrake lever. ( p. 90)
K01343-10
13.2 Adjusting the free travel of the handbrake lever
– Check the free travel of the hand brake lever. ( p. 90)
– Adjust the free travel of the handbrake lever with adjustment
screw1.
Info
Turn the adjusting screw clockwise to reduce free
travel. The pressure point moves away from the
handlebar.
K01343-11
Turn the adjusting screw counterclockwise to increase
free travel. The pressure point moves towards the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not
apply any force.
Do not make any adjustments while riding.
≥ 3 mm (≥ 0.12 in)
13.3 Checking the brake discs
Warning
Danger of accidents Worn-out brake discs reduce the braking effect.
– Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will
be glad to help.)
90
Page 93
400257-10
BRAKE SYSTEM 13
– Check the front and rear brake disc thickness at multiple
points for the dimensionA.
Info
Wear reduces the thickness of the brake disc around
the contact surface of the brake linings.
Brake discs - wear limit
front 2.5 mm (0.098 in)
rear 3.5 mm (0.138 in)
» If the brake disc thickness is less than the specified value:
– Change the front brake disc.
– Change the rear brake disc.
– Check the front and rear brake discs for damage, cracking, and
deformation.
» If the brake disc exhibits damage, cracking, or deforma-
tion:
– Change the front brake disc.
– Change the rear brake disc.
13.4 Checking the front brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is
leaking or the brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)
– Move the brake fluid reservoir mounted on the handlebar to a
horizontal position.
–
Check the brake fluid level in level viewer1.
»
If the brake fluid level has dropped below the markingA:
– Add the front brake fluid. ( p. 92)
V01847-10
91
Page 94
13 BRAKE SYSTEM
13.5 Adding the front brake fluid
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is
leaking or the brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
Preparatory work
– Check the front brake linings. ( p. 93)
Main work
– Move the brake fluid reservoir mounted on the handlebar to a
horizontal position.
–
Remove screws1.
–
Take off cover2with membrane3.
–
Add brake fluid to levelA.
Guideline
E01210-10
LevelA(brake fluid level
below reservoir rim)
5 mm (0.2 in)
92
Brake fluid DOT 4 / DOT 5.1 ( p. 149)
Page 95
– Position the cover with the membrane. Mount and tighten the
screws.
Info
Immediately clean up any brake fluid that has overflowed or spilled with water.
13.6 Checking the front brake linings
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be
glad to help.)
–
Check the brake linings for minimum thicknessA.
BRAKE SYSTEM 13
≥ 1 mm (≥ 0.04 in)
E00342-10
Minimum thickness
» If the minimum thickness is less than specified:
– Change the brake linings of the front brake.
( p. 93)
– Check the brake linings for damage and cracking.
» If damage or cracking is visible:
– Change the brake linings of the front brake.
( p. 93)
A
13.7 Changing the brake linings of the front brake
Warning
Danger of accidents Incorrect servicing will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop
will be glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)
93
Page 96
13 BRAKE SYSTEM
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient
of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologation is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the
manufacturer warranty shall be void.
– Only use brake linings approved and recommended by KTM.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
– Move the brake fluid reservoir mounted on the handlebar to a
horizontal position.
–
Remove screws1.
–
Take off cover2with membrane3.
– Manually press the brake caliper toward the brake disc to push
back the brake pistons. Ensure that brake fluid does not flow
out of the brake fluid reservoir; extract some if necessary.
E01210-12
–
– Clean the brake caliper and the brake caliper bracket.
Info
Make sure that you do not press the brake caliper
against the spokes when pushing back the brake
pistons.
Remove cotter pin4, pull out pin5, and remove the brake
linings.
94
E00344-10
Page 97
100397-01
E00345-10
BRAKE SYSTEM 13
–
Check that spring plate6in the brake caliper and sliding
plate7in the brake caliper bracket are seated properly.
–
Insert the new brake linings, insert the pin, and mount the cot-
ter pins.
Info
Always change the brake linings in pairs.
– Operate the hand brake lever repeatedly until the brake lin-
ings are in contact with the brake disc and there is a pressure
point.
–
Correct the brake fluid level to levelA.
Guideline
LevelA(brake fluid level
below reservoir rim)
Brake fluid DOT 4 / DOT 5.1 ( p. 149)
– Position the cover with the membrane. Mount and tighten the
screws.
E01210-11
5 mm (0.2 in)
Info
Immediately clean up any brake fluid that has overflowed or spilled with water.
13.8 Checking the free travel of foot brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear
brake.
– Set the free travel on the foot brake lever in accordance with the specification.
402026-10
–
Disconnect spring1.
– Move the foot brake lever back and forth between the end stop
and the contact to the foot brake cylinder piston and check
free travelA.
Guideline
Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in)
» If the free travel does not meet specifications:
95
Page 98
13 BRAKE SYSTEM
13.9 Adjusting the basic position of the foot brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear
brake.
– Set the free travel on the foot brake lever in accordance with the specification.
– Adjust the basic position of the foot brake lever.
( p. 96)
–
Reconnect spring1.
–
Detach spring1.
–
Loosen nut4and, with push rod5, turn it back until you
have maximum free travel.
– To adjust the basic position of the foot brake lever to individ-
ual requirements, loosen nut2and turn screw3accordingly.
Info
The range of adjustment is limited.
–
Turn push rod5accordingly until you have free travelA. If
necessary, adjust the basic position of the foot brake lever.
Guideline
Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in)
–
Hold screw3and tighten nut2.
Guideline
K00563-10
Nut, foot brake lever
stop
–
Hold push rod5and tighten nut4.
Guideline
Remaining nuts,
chassis
–
Attach spring1.
M8 20 Nm (14.8 lbf ft)
M6 10 Nm (7.4 lbf ft)
13.10 Checking the rear brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is
leaking or the brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
96
Page 99
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)
– Stand the vehicle upright.
–
Check the brake fluid level in level viewer1.
»
If the brake fluid level has dropped below markingA:
– Add rear brake fluid. ( p. 97)
V01818-10
13.11 Adding rear brake fluid
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is
leaking or the brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
BRAKE SYSTEM 13
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact
with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service
schedule. (Your authorized KTM workshop will be glad to help.)
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not
designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
97
Page 100
13 BRAKE SYSTEM
Preparatory work
– Check the rear brake linings. ( p. 98)
Main work
– Stand the vehicle upright.
–
Remove screw cap1with membrane2and the O-ring.
–
Add brake fluid to levelA.
Brake fluid DOT 4 / DOT 5.1 ( p. 149)
– Mount the screw cap with the membrane and the O-ring.
Info
Clean up overflowed or spilled brake fluid immediately
with water.
K01347-10
13.12 Checking the rear brake linings
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be
glad to help.)
–
Check the brake linings for minimum thicknessA.
≥ 1 mm (≥ 0.04 in)
E00349-10
Minimum thickness
» If the minimum thickness is less than specified:
– Change the rear brake linings. ( p. 98)
– Check the brake linings for damage and cracking.
» If damage or cracking is visible:
– Change the rear brake linings. ( p. 98)
A
13.13 Changing the rear brake linings
Warning
Danger of accidents Incorrect servicing will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop
will be glad to help.)
98
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