KTM 990 Adventure 2006 Owner's manual

990 ADVENTURE

990 ADVENTURE S

ART. NR. 3.211.81 EN

OWNER’S MANUAL 2006

All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models. © 2005 by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTM-SPORTMOTORCYCLE AG, Mattighofen only.

COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may prohibit: (a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorpo-

rated 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; and

(b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Frame number

Engine number

Key number

Stamp of dealer

INTRODUCTION »

We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately. Please insert the serial numbers of your motorcycle in the boxes below:

In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality.

IMPORTANT INFORMATION »

INTENDED PURPOSE

The KTM 990 Adventure is designed to resist the usual wear and tear of normal use on roads and easy terrain (unpaved roads).

OWNER'S MANUAL

Carefully read the entire Owner's Manual before you start riding your motorcycle, even if this will take a little time. It contains useful tips and information on the best way to handle the motorcycle and how to protect yourself from injuries. The Manual also contains important information on service and maintenance. In your own interest, pay particular attention to the information marked as follows:

– Ignoring these instructions, can endanger your body and

your life.

– Ignoring these instructions could cause damage to parts

of your motorcycle or that the motor-cycle is not road-safe anymore.

The Owner's Manual corresponded to the latest information available for this model series at the time it was printed. Minor deviations resulting from enhancements to the motorcycle design cannot be entirely precluded. The Owner's Manual is an integral part of the motorcycle and must be handed over to the new owner when the motorcycle is sold.

SERVICE

Observance of the service, maintenance and operating instructions for the engine and chassis specified in the Owner's Manual is a prerequisite for faultless operation and the avoidance of premature wear. Please observe the prescribed breaking-in periods, inspection intervals and service intervals. Strict observance will significantly prolong the service life of your motorcycle.

Use of the motorcycle under extreme conditions, e.g. on extremely muddy and wet terrain, can lead to higher than average wear on components such as the drive train or the brakes. In this case it may become necessary to service or replace wear parts before the service limit specified in the maintenance schedule has been reached.

IMPORTANT INFORMATION »

WARRANTY

The service work specified in the „Lubrication and Maintenance Schedule“ must be performed by an authorized KTM workshop. This is the only place that has the qualified technicians and the special tools required for the 990 Adventure. Be sure to have the workshop verify all service work carried out in the service manual to avoid losing your right to claim under the warranty. The warranty or guarantee shall become void for damage and consequential damage caused by manipulations or conversions to the motorcycle.

AUTOMOTIVE FLUIDS

The fuels, lubricants and liquids specified in the Owner's Manual or automotive fluids with equivalent specifications must be used in accordance with the maintenance schedule.

SPARE PARTS, ACCESSORIES

For your own safety, only use spare parts and accessories approved by KTM. KTM shall not assume any liability for other products or consequential damage resulting from the use of such products.

ENVIRONMENT

Motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full. It may, however, involve potential problems for the environment or lead to conflicts with others. These problems or conflicts can be avoided if the motorcycle is used responsibly. To safeguard the future of motorcycle sports, make sure that you use the motorcycle in accordance with the law, show that you are environmentally conscious and respect the rights of others.

Enjoy driving your motorcycle !

KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN, AUSTRIA

INDEX »

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . .2

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . .6

Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Engine number, engine type . . . . . . . . . . . . . . . . . . . . . . . .6

OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . .7

Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Multi-functional digital speedometer . . . . . . . . . . . . . . . . .8

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Setting options in the display . . . . . . . . . . . . . . . . . . . . . .10

Cooling liquid temperature display . . . . . . . . . . . . . . . . . .12

Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

ABS warning lamp – models with ABS

(antilock brake system) . . . . . . . . . . . . . . . . . . . . . . . . . .14

ABS button – models with ABS (antilock brake system) . . .14

Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Emergency OFF tip switch, starter tip switch . . . . . . . . . . .16

Storage compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Filler caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Seat lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Fuel taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Center stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Compression damping of fork . . . . . . . . . . . . . . . . . . . . . .20

Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . . . .20

Spring preload of the fork . . . . . . . . . . . . . . . . . . . . . . . . .20

Damping action during compression of shock absorber . . . .21

Rebound damping of shock absorber . . . . . . . . . . . . . . . . .22

Shock absorber's preload adjuster . . . . . . . . . . . . . . . . . . .22

Baggage carrier plate . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

GENERAL TIPS AND WARNINGS FOR STARTING

THE MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Instructions for initial operation . . . . . . . . . . . . . . . . . . . .24

Running in the LC8 engine . . . . . . . . . . . . . . . . . . . . . . . .24

Accessories and payload . . . . . . . . . . . . . . . . . . . . . . . . . .25

DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . .26

Check the following before each start . . . . . . . . . . . . . . . .26

Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Braking – models without ABS (antilock brake system) . . . .30

Braking – models with ABS (antilock brake system) . . . . . .30

Switching off the ABS . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . .36

MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . . . . .40

Removing and remounting the seat . . . . . . . . . . . . . . . . . .41

Tool set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Adjusting the fork and shock absorber . . . . . . . . . . . . . . .42

Adjusting compression damping of fork . . . . . . . . . . . . . . .42

Adjusting rebound damping of fork . . . . . . . . . . . . . . . . . .42

Adjusting the spring preload on the fork . . . . . . . . . . . . . . .43

INDEX »

Compression damping of shock absorber . . . . . . . . . . . . . .44

Rebound damping of shock absorber . . . . . . . . . . . . . . . . .45

Adjusting the preload of the shock absorber . . . . . . . . . . . .46

Breathing the fork legs . . . . . . . . . . . . . . . . . . . . . . . . . .46

Cleaning the dust sleeves of the telescopic fork . . . . . . . . .47

Checking the chain tension . . . . . . . . . . . . . . . . . . . . . . .47

Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Checking the chain for wear . . . . . . . . . . . . . . . . . . . . . . .49

General informations about KTM disc brakes . . . . . . . . . . .50

Adjusting of free travel at the hand brake lever . . . . . . . . . .53

Checking of brake fluid level - front brake . . . . . . . . . . . . .53

Checking the front brake pads . . . . . . . . . . . . . . . . . . . . .53

Checking rear brake fluid level . . . . . . . . . . . . . . . . . . . . .54

Checking the rear brake pads . . . . . . . . . . . . . . . . . . . . . .54

Dismounting and mounting the front wheel . . . . . . . . . . . .56

Dismounting and mounting the rear wheel . . . . . . . . . . . . .58

Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Checking spoke tension . . . . . . . . . . . . . . . . . . . . . . . . . .60

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Demounting and mounting the battery . . . . . . . . . . . . . . . .62

Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Jump start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Main fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

ABS fuses – models with ABS (antilock brake system) . . . . .64

Fuses for individual current consumers . . . . . . . . . . . . . . .65

Replacing the headlight lamps . . . . . . . . . . . . . . . . . . . . .66

Adjusting the headlight range . . . . . . . . . . . . . . . . . . . . . .68

Replacing the brake and tail light bulbs . . . . . . . . . . . . . . .68

Replacing the flasher bulbs . . . . . . . . . . . . . . . . . . . . . . .69

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Checking the cooling liquid level in the compensating tank .71

Checking the cooling liquid level in the radiator . . . . . . . . .72

Bleeding the cooling system . . . . . . . . . . . . . . . . . . . . . . .73

Changing the original position of the clutch lever . . . . . . . .74

Checking the oil level of the hydraulic clutch . . . . . . . . . . .74

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Checking the engine oil level . . . . . . . . . . . . . . . . . . . . . .75

Changing the engine oil and the oil filter,

cleaning the oil screen . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Activating the ignition curve for low-octane fuel . . . . . . . . .82

TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

CONSERVATION FOR WINTER OPERATION . . . . . . . . . . . . . .88

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

TECHNICAL SPECIFICATIONS – CHASSIS . . . . . . . . . . . . . . .90

TECHNICAL SPECIFICATIONS – ENGINE . . . . . . . . . . . . . . .94

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

Chassis number

The chassis number is located on the right side of the steering head tube and on the type label. Write this number into the relevant area on page 1.

Engine number, engine type

The engine number and engine type are embossed in the engine case near the shift lever. Write this number into the relevant area on page 1.

SERIAL NUMBER LOCATIONS »

Clutch lever

The clutch lever [1] is located on the left side of the handlebar. The adjusting screw [A] is used to change the original position of the clutch lever (see maintenance work on chassis and engine). The clutch is hydraulically actuated and adjusts itself automatically.

Hand brake lever

The hand brake lever [2] is mounted on the handlebars on the right and actuates the front wheel brake. The adjusting screw [B] can be used to change the basic position of the hand brake lever (see Maintenance).

OPERATION INSTRUMENTS »

Multi-functional digital speedometer

The universal instrument is divided into 3 parts. Use the MODE and SET [1] button to change the display and the basic settings in the display.

Display [2] shows all of the information that may be of interest to you. 5 display modes can be selected with the MODE button.

The indicator lamps [3] provide additional information on the motorcycle's running condition.

Display

TEST When you switch on the ignition, all of the display elements will light up for 1 second for the function test.

WS (wheel size) The display will change and show the diameter of the front wheel in inches for 1 second (WS = wheel size). Then the CLOCK mode will be displayed, or the mode that was active when the ignition was switched off.

OPERATION INSTRUMENTS »

TEST

321

CLOCK You will recognize the CLOCK display by the blinking dots between the hours and minutes. It displays the speed, temperature of the cooling liquid and the clock. To switch to the next display mode, press the MODE button.

ODO The speed, temperature of the cooling liquid and the total kilometers or miles traveled are shown in the ODO mode. To switch to the next display mode, press the MODE button.

TRIP 1 The TRIP 1 mode shows the speed, the temperature of the cooling liquid and the trip odometer 1. To switch to the next display mode, press the MODE button.

TRIP 2 The TRIP 2 mode shows the speed, the temperature of the cooling liquid and the trip odometer 2. To switch to the next display mode, press the MODE button.

TRIP F The TRIP F (fuel) mode shows the speed, the temperature of the cooling liquid and the distance traveled since reaching the low-fuel mark (the low-fuel indicator lamp lights up). To return to the CLOCK mode, press the MODE button.

OPERATION INSTRUMENTS »

ODO

CLOCK

TRIP 1

TRIP 2

TRIP F

Setting options in the display

KILOMETERS OR MILES. You can have the speed and distance shown in kilometers or miles in the display. The display can be adapted to the respective country on long-distance trips. To switch from kilometers to miles, switch on the ignition and press the MODE [1] button for approx. 10 seconds. The km/h display will switch to mph. The speed and the stored distances will be converted and displayed in miles. To return to kilometers, proceed as described above.

CLOCK Switch on the ignition and change to the CLOCK mode. Simultaneously press MODE [1] and SET [2]. The numbers on the clock will start to blink. Use the MODE button to set the hours and the SET button to set the minutes. The press the MODE and SET buttons simultaneously.

NOTE: 0:00 will be displayed if the clock is not supplied with electricity. This can be caused by a defective fuse or a fault in the board electric system (see Troubleshooting).

TRIP 1 The trip meter 1 runs continuously and counts up to 999.9. It can be used to measure the length of a certain route on a trip or the distance between two refueling stops. To return the trip meter 1 to zero, switch on the ignition, change to the TRIP 1 mode and press the SET button.

OPERATION INSTRUMENTS »

10 sec

RESETTING TRIP 2 The trip meter 2 runs continuously and counts up to 999.9. It can be used similarly to TRIP 1 or together with a switch available as an accessory (see below) for trips according to a roadbook. To return the trip meter 2 to zero, switch on the ignition, change to the TRIP 2 mode and press the SET button.

NOTE: A Tripmaster switch (Part no. 582.14.069.044) is available as an accessory and enhances the trip meter 2 functions. You can correct the displayed route by increasing or decreasing in increments of 0.1. For example, if you have taken the wrong road when driving according to a roadbook, you can easily correct the display to correspond to the roadbook again. It can also be used to change the display modes. The switch is mounted on the handlebars so that you can keep your hands on the handlebars.

TRIP F When the fuel level reaches the reserve mark, the display will automatically switch to TRIP F and begin to count (no matter which display mode was active before). At the same time, the fuel warning lamp will light up. You will still have enough reserve fuel for at least 30 kilometers. After refueling, it will take approx. 8 minutes for the fuel warning lamp to switch off and for TRIP F to automatically reset to 0 and return to the previous display mode.

NOTE: Press the SET key for 2 seconds to immediately turn off the fuel warning lamp.

OPERATION INSTRUMENTS »

120°C (248°F)

110°C (230°F)

100°C (212°F)

70°C (158°F)

60°C (140°F)

50°C (122°F)

40°C (104°F)

Cooling liquid temperature display

The temperature display [1] is shown in 7 bars. The more bars that light up, the hotter the cooling liquid. When the lowest bar lights up, the cooling liquid has reached a temperature of approx. 40°C (104°F). When the upper bar lights up 120°C (248°F), all of the bars will start to blink and the red warning lamp [2] will light up.

Possible causes for an increase in temperature, causing the red warning light for the cooling liquid temperature to light up:

– Driving too slowly and driving with a heavy load at high air temperatures – Not enough cooling liquid in the system – The ventilator on the radiator is not running – Improper use of the clutch when driving slowly

OPERATION INSTRUMENTS »

Indicator lamps

The green indicator lamp will blink in the blinker rhythm when the blinker is switched on. NOTE: The indicator lamp will blink slower when a blinker is broken.

The green indicator lamp will light up when the gearbox is in an idling position.

The blue indicator lamp will light up when the high beams are switched on.

The red warning light will light up when the cooling liquid has reached a temperature of approx. 120°C (248°F).

The orange warning light will

light up

when the fuel level has reached the reserve

mark. At the same time the display will automatically change to TRIP F (see TRIP F).

The red warning lamp lights up when the ignition is switched on but the engine is not running. When the engine is started, the warning lamp will go out as soon as the oil pressure is high enough.

The orange warning lamp (fuel injection) briefly lights up when the ignition is switched on. It will go out when the gasoline pressure is high enough. If this warning lamp lights up while driving, a component in the injection system is defective. The error can be identified by means of a blink code (see Trouble shooting).

OPERATION INSTRUMENTS »

ABS warning lamp – models with ABS (antilock brake system)

The ABS warning lamp [1] must light up when the ignition is switched on and go out at a speed of approx. 5 KPH after you drive off. If it stays on or lights up while driving, the ABS is defective. The ABS is no longer active and the wheels can lock when braking.

NOTE: The brake system will still function but ABS control will no longer be active. Continue to drive carefully and have the ABS checked at an authorized KTM workshop.

NOTE: The ABS warning lamp can also light up if there is a large deviation between the speed of the front and rear wheel in extreme driving situations, e.g. during a wheelie or if the rear wheel slips when accelerating on loose ground. The ABS will no longer be active and the wheels can lock when braking. To activate the ABS again, stop and switch off the ignition. If the warning lamp goes off again at a speed of approx. 5 KPH after you drive off, the ABS is active and fully operative.

ABS button – models with ABS (antilock brake system)

The ABS button [2] switches off the ABS. To switch off the ABS, stop the motorcycle and press the ABS button for at least 3 seconds with the engine running. Let go of the ABS button as soon as the ABS warning lamp starts blinking fast. The ABS warning lamp will blink slowly to indicate that the ABS is switched off. To switch the ABS on again, stop and switch off the ignition. The ABS will be active again when you switch on the ignition.

OPERATION INSTRUMENTS »

Tachometer

The tachometer shows the engine speed in revolutions per minute. Do not run the engine beyond the black mark at 9500 rpm. The speed limiter will set in at 9600 rpm, drastically reducing the engine power above this rotational speed. When you switch on the ignition, the indicating needle will move to the black mark and back again.

Ignition lock

The ignition lock [1] has 3 switching positions.

Ignition off, (engine can't be started)

Ignition on, (engine can be started)

Ignition off, handlebar blocked

To switch the ignition to position turn the ignition key to position and firmly press it into the lock. Turn the handlebar to the left, then turn the ignition key to the left.

The ignition key can be withdrawn in position and .

OPERATION INSTRUMENTS »

Combination switch

The rocker switch LIGHTS [1] actuates the high beam or low beam.

= High-beam light

= Low-beam light

The light signal (high beam) is actuated with button [2].

The indicator switch [3] returns to central position after actuation. Press flasher switch towards switch housing to switch off the flasher.

The horn is sounded with button [4].

Emergency OFF tip switch, starter tip switch

The emergency off switch [5] is provided for emergency situations and should not be used to switch off the engine. The engine is ready for operation in position (ignition circuit and starter circuit are switched on). The engine cannot be started in position (ignition circuit and starter circuit are interrupted).

Use the starter tip switch [6] to operate the electric starter.

OPERATION INSTRUMENTS »

Storage compartment

A storage compartment is located under the seat to hold small, frequently used items. To open, turn the quick release [1] approx. 180° in a counterclockwise direction and lift the cover. To lock, close the cover, insert the quick release in the dolly and turn 180° in a clockwise direction.

Filler caps

The 990 Adventure has 2 separate fuel tanks. Both filler caps [2] can be locked and are equipped with a tank vent system. To open, insert the ignition key, turn 45° in a clockwise direction and fold up the filler cap. The ignition key can be pulled out to open the other filler cap. Simply press on the filler cap to close.

Seat lock

The seat is unlocked by inserting the ignition key in the lock [3] on the side and turning the key in a counterclockwise direction. See "Maintenance Work" to remove and remount the seat.

OPERATION INSTRUMENTS »

2,3,4,5,6

Fuel taps

Both fuel taps [1] must be open when the motorcycle is running. The level in the fuel tanks is equalized by means of a connecting hose. Only close the fuel taps to remove the tanks.

Shift lever

The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear.

OPERATION INSTRUMENTS »

Center stand

The bike is equipped with a side stand and a center stand [2].

Foot brake pedal

The foot brake pedal [3] is located in front of the right footrest. Its basic position can be adjusted to your seat position (see maintenance work).

Side stand

Fold the side stand [1] forward to the stop with your foot and put the weight of the motorcycle on the stand. Make sure it is standing securely on a firm surface. The side stand is linked to the safety start system; follow the driving instructions.

OPERATION INSTRUMENTS »

Compression damping of fork

The fork's damping action during compression travel (compression damping) can be adjusted. This allows you adjust the damping behavior to match your driving style and the payload. The adjusting screws [2] are located under the cap [1] on the lower end of the fork legs. More information is provided in the chapter "Adjusting the fork and shock absorber.“

Rebound damping of fork

The fork's damping action during rebound travel (rebound damping) can also be adjusted. This allows you adjust the damping behavior to match your driving style and the payload. The adjusting screws [3] are located on the upper end of the fork legs. More information is provided in the chapter "Adjusting the fork and shock absorber.“

Spring preload of the fork

The fork's preload can be adjusted by means of the adjusting screws [4]. More information is provided in the chapter "Adjusting the fork and shock absorber.“

OPERATION INSTRUMENTS »

Damping action during compression of shock absorber

The shock absorber's damping action during compression travel (compression damping) can be adjusted. This allows you adjust the shock absorber's damping behavior to match your driving style and the payload. The damping rate can be adjusted in the low and high-speed range (Dual Compression Control). The designation low and high-speed refers to the movement of the shock absorber and not to the motorcycle's driving speed.

The adjusting screw [1] for the low-speed range can be adjusted with a screwdriver.

The adjusting screw [2] for the high-speed range can be adjusted with a 17 mm socket wrench.

More information is provided in the chapter "Adjusting the fork and shock absorber.“

OPERATION INSTRUMENTS »

Rebound damping of shock absorber

The shock absorber's damping action during rebound travel (rebound damping) can also be adjusted. This allows you adjust the damping behavior to match your driving style and the payload. The adjusting screw [1] is located on the bottom of the shock absorber. More information is provided in the chapter "Adjusting the fork and shock absorber.“

Shock absorber's preload adjuster

The shock absorber's preload adjuster is infinitely variable by means of the hand wheel [2]. This allows the shock absorber to be adapted to match your body weight and the payload. The hand wheel can be swung out to make adjustments.

OPERATION INSTRUMENTS »

Baggage carrier plate

The base plate for your choice of case system can be attached to the baggage carrier plate [1].

– Do not load more than 8 kg on the trunk carrier rack. – Observe the baggage manufacturer's instructions.

Grips

The passenger can hold on to both grab handles [2].

Footrests

The passenger footrests [3] fold up.

Instructions for initial operation

– Make sure the work for the „pre-delivery

inspection“ was performed by your authorized KTM workshop. The DELIVERY CERTIFICATE and SERVICE MANUAL will be handed over when you pick up your vehicle.

– Read these operating instructions care-

fully before your first ride.

– Enter the chassis, engine and key num-

bers on page 1.

– Familiarize yourself with the operating

elements.

– Adjust the hand brake lever and foot brake

lever to your most comfortable position.

– The motorcycle is equipped with 2 three-

way catalysts. Leaded fuel will destroy the catalytic converters. Please use unleaded fuel only.

– Get used to handling the motorcycle on

an empty parking lot, before starting on a longer drive. Also try to drive as slowly as possible and in standing position, to improve your feeling for the vehicle.

– Do not drive along off-road tracks which

go beyond your abitily and experience.

– Hold the handlebars with both hands and

leave your feet on the foot rests while driving.

– Remove your foot from the foot brake

lever when you are not braking. If the foot brake lever is not released the brake pads rub continuously and the braking system is overheated.

– Do not make any alterations to the motor-

cycle and always use ORIGINAL KTM

SPARE PARTS. Spare parts from other manufacturers can impair the safety of the motorcycle.

– New tires have a smooth surface, which

means that they must be run in to achieve full grip. For this purpose, ride the motorcycle carefully at moderate speed during the first 200 kilometers with new tires, tilting the vehicle at different angles so that all sections are properly roughened. Tires will not display their full grip characteristics until they are properly run in.

– Motorcycles are sensitive to changes in

the weight distribution. Read the section on "Accessories and payload“ when carrying luggage.

– Pay attention to running-in procedure.

Running in the LC8 engine

Even finely machined surfaces of engine parts have rougher surfaces than parts that slide on each other for a long time. Therefore, every engine must be run in. For this reason, do not demand maximum performance from the engine for the first 1000 kilometers (620 miles). The vehicle must be run in at low, changing performance level for the first 1000 km (620 miles). The maximum number of revolutions per minute must not go exceed 6500 rpm. Once you have run your engine in for 1000 km, you may push it to its 9500 rpm limit , i.e. up to the black zone indicated in the tachometer. Exceeding the above listed rotations as well as pushing high rpm when the engine is cold will have an adverse effect on the life of your engine.

– Wear suitable clothing when driving a

motorcycle. Clever KTM drivers always wear a helmet, boots, gloves and a jacket, regardless of whether driving all day or just for a short trip. The protective clothing should be brightly colored so that other vehicle can see you as early as possible. Your passenger will also need suitable protective clothing.

– Do not drive after having consumed

alcohol.

– Always turn on the light to make sure

that other drivers become aware of you as early as possible.

– Drive at a moderate speed for the first few

kilometers of each trip to allow the tires to reach the necessary operating temperature. Maximum road grip is assured when the tires are warm.

– The front and rear wheel are allowed to

be fitted only with tires that have the same profile type.

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE »

– The tires must be designed for a maxi-

mum speed of 240 kph (speed symbol V) and must be authorized by KTM.

– Do not exceed the respective maximum

speed for tires designed with a speed index of less than "V“ (240 kph). A sticker showing the maximum speed must be affixed to the motorcycle within the driver's field of vision.

– New wheels have a smooth surface, which

– Wheels with a different rim diameter or

other rim width may not be mounted otherwise the vehicle handling will no longer be safe. For models equipped with ABS (antilock brake system), the ABS function is no longer guaranteed.

– Models with ABS: The ABS is designed

to be used with the tires authorized by KTM and works best with these tires. The ABS function cannot be guaranteed if other tires are used.

– Models with ABS: an incorrect tire pres-

sure will have an adverse effect on the ABS control and driving stability and will increase the stopping distance.

– Observe the traffic regulations, drive

defensively and trying to look ahead as far as possible so that any hazards can be recognized as early as possible.

– The faster you drive, the more sensitive

your motorcycle will be to crosswind and changing road conditions. Your motorcycle can easily go out of control at high speeds.

– Choose your driving speed according to

the conditions and your driving skills.

– Drive carefully on unknown roads or on

unfamiliar trials.

– Renew the vizor on your helmet or the glass

of your goggles on time so as to ensure optimum vision in any situation. When light shines directly on scratched visor or goggles, the operator will be blinded.

– Never leave your motorcycle without super-

vision if the engine is running.

Accessories and payload

Accessory parts and baggage can significantly decrease a motorcycle's driving stability. Please observe the following warnings.

– Never drive faster than 130 kph (80 mph)

if you have mounted accessory parts on your motorcycle. Accessory parts can significantly impair the motorcycle's handling, especially in the maximum speed range.

– Never drive faster than 130 kph (80 mph)

if your motorcycle is loaded with cases or other baggage. They will impair the motorcycle's handling at higher speeds and can easily cause it to go out of control

– If you have cases mounted, do not exceed

the manufacturer's recommended maximum payload.

– Fasten the baggage close to the center

of the motorcycle and distribute the weight evenly on the front and rear wheels and on the left and right.

– Baggage must be securely and adequately

fastenend; loose baggage will significantly impair driving safety.

– A high payload will change the motorcy-

cle's handling and considerably increase the braking distance; adapt your driving speed accordingly.

– Never exceed the maximum permissible

laden weight and the axle weights. The maximum permissible laden weight is made up of the following components: – Motorcycle ready for operation and tank

full – Luggage – Driver and passenger with protective

clothing and helmet

Check the following before each start

When you start, the motorcycle must be in perfect mechanical condition. For safety reasons, you should make a habit of performing an overall check of your motorcycle before each start.

The following checks should be performed:

1 FUEL

Check the fuel quantity in the tanks.

2 CHAIN

Check the tension and condition of the chain. A loose chain can fall off the sprockets and a worn-out chain can tear. In both cases this can damage other motorcycle components and cause the motorcycle to go out of control. A chain that is too tight or not greased will cause unnecessary wear to the chain and sprockets.

3 TIRES

Check for damaged tires. Tires showing cuts or dents must be replaced. The tread depth must comply with the legal regulations. Also check the air pressure. Insufficient tread and incorrect air pressure deteriorate the driving performance.

4 BRAKES

Check correct functioning of the braking system. Check for sufficient brake fluid in the reservoir. The reservoirs have been designed in such a way that brake fluid does not need to be refilled even when the brake pads are worn. If the level of brake fluid falls below the minimum value, this indicates a leak in the braking system or completely worn out brake pads. Arrange for the braking system to be checked by a KTM specialist, as complete failure of the braking system can be avoided. Also check the state of the brake hose and the thickness of the brake linings. Check free travel at hand brake lever and foot brake lever.

5 CABLES

Check smooth operation of the throttle cables.

DRIVING INSTRUCTIONS »

6 COOLING FLUID

Check the level of cooling fluid when the engine is cold.

7 ELECTRICAL SYSTEM

Start the engine and check the headlight, taillight, brake light, turn signal, indicator lamps and horn for proper functioning.

8 CHECK OIL LEVEL

Insufficient oil results in premature wear and consequently to engine damage.

9 BAGGAGE, PAYLOAD

Never exceed the maximum total weight (430 kg, 949 lbs) and the motorcycle's wheel loads. The maximum total weight is comprised of: – the motorcycle in a running condition and refueled (232 kg, 512 lbs) – the baggage and accessories – the driver and passenger with protective gear and helmet Adjust the tire inflation pressure as well as the preload and damping properties of the fork and shock absorber to the total weight. Make sure your luggage is correctly fastened before you drive off.

Never drive faster than 130 kph (80 mph) if your motorcycle is loaded with cases or other baggage. They will impair the motorcycle's handling at higher speeds and can easily cause it to go out of control.

10 REAR MIRROR

Sit on the motorcycle and check the adjustment of the rear mirror.

DRIVING INSTRUCTIONS »

Starting the engine

1 Switch on emergency OFF switch [1]. 2 Switch on ignition (turn ignition key [2] into position ).

NOTE: You will hear the operation of the fuel pump for approx. 2 seconds after switching on the ignition. The FI indicator lamp will also light up during this time and the engine should not be started.

3 NOTE FOR MODELS WITH ABS:

The ABS warning lamp [5] must light up when the ignition is switched on. 4 Switch transmission to idle (green indicator lamp N [3] lights up). 5 Do not accelerate; operate starter button [6].

NOTE: If you accelerate during the starting process you will hear a loud, metallic

sound caused by the torque limiter. The torque limiter protects the

components in the starter drive from being damaged. 6 The oil pressure warning lamp [4] should go out as soon as the engine is running. 7 Take the motorcycle off of the main stand or side stand.

– Do not start the engine and allow it to idle in a closed room. Exhaust fumes are poison-

ous and can cause loss of consciousness and death. Always provide adequate ventila-

tion while the engine is running.

– Never operate the motorcycle with a run-down battery or without the battery. This can

damage the electronic components or safety equipment in either caseand the motorcy-

cle will no longer be roadworthy.

– If you accelerate while starting, the engine management will not inject any fuel and the

engine will not start. Do not accelerate while starting!

– If the oil pressure warning lamp does not go out as soon as the engine is running, imme-

diately switch off the engine. If the engine is not switched off, engine damage will occur

within a short period of time. Check the engine oil level or contact a ktm workshop.

– Maximum period for continuous starting: 5 seconds. Wait at least 5 seconds before try-

ing again.

– Don’t ride your motorcycle with full load and don’t rev engine when cold. Because the

piston is warming up faster than the water cooled cylinder, it can cause engine damage.

Always let the engine warm up before and refrain from driving with full load until the

engine is warm.

IF THE ENGINE IS DOES NOT CRANK WHEN YOU ACTUATE THE STARTER TIP SWITCH:

– the transmission is switched to idle – Check if the emergency OFF switch is on – Check if the ignition is on – the headlight is on (the light is switched

off when actuating the starter button) – If this is not the case, the battery is dis-

charged

– If the lights are on, proceed as described

in the „Trouble-shooting“ section or contact a KTM dealer.

IF THE ENGINE CRANKS BUT DOES NOT START, WHEN YOU ACTUATE THE STARTER TIP SWITCH:

– whether you accelerated while starting – whether the FI indicator lamp is blinking

– if yes, check Troubleshooting - Blink

codes table

– Check if sufficient fuel is in the tank

– If this is not the case, refill the tank – if sufficient fuel is in the tank, pro-

ceed as described in the „Troubleshooting“ section or contact a KTM dealer.

NOTE: This motorcycle is equipped with a safety starting system. The engine can only be started if the transmission is in neutral or the clutch lever is pulled. If the side stand is folded down, the engine can only be started if the transmission is in neutral or the clutch lever is

pulled. The engine will stall if a gear is engaged and the clutch lever is released with the side stand folded down.

Starting off

Pull the clutch lever and engage 1st gear. Slowly release the clutch lever while you gently accelerate.

Before you start off, check that the main stand has been swung up fully. If the stand drags on the ground, the motorcycle can go out of control.

Shifting/Riding

You are now in first gear, refered to as the drive or uphill gear. Depending on the conditions (traffic, road gradient, etc.), you can shift to a higher gear. Close throttle, at the same time pull clutch lever and shift to the next higher gear. Let clutch lever go again and carefully open throttle. Do not shift gears and accelerate carefully in curves. Only accelerate to the extent that road and weather conditions allow. Be especially careful when you accelerate in curves. Abrupt opening of the throttle can cause the motorcycle to go out of control and also increases fuel consumption. By shifting down, use the brakes if necessary and close throttle at the same time. Pull clutch lever and shift down to the next gear. Let clutch lever go slowely and open throt-

tle or shift down again. If the engine is killed f.ex. at a crossing, simply pull the clutch lever and start. It is not necessary to switch the gear to NEUTRAL. Stop immediately if the FI indicator lamp lights up while driving. The FI indicator lamp will start blinking as soon as the transmission is in neutral. The rhythm of the blinking lamp will let you determine the two-digit „blink code“, e.g.: Blink code 34: FI blinks 3x long, 4x short, pause, Blink code 06: FI blinks 6x short, pause. The blink code will indicate which component is defective (see Troubleshooting). This makes it possible to pinpoint the defect if a diagnostic tool is unavailable.

– Avoid abrupt load changes while riding

around bends and on wet or slippery ground. Otherwise you might easily lose control over your motorcycle.

DRIVING INSTRUCTIONS »

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