KTM 990 SUPERMOTO T Manual

OWNER’S MANUAL 2008

990 SUPERMOTO

ART. NR. 3211247en

INTRODUCTION »

1

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:

Frame number	Stamp of dealer

Engine number

Key number

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.

© 2007 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 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; and

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

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 »

2

INTENDED PURPOSE

The 990 Supermoto is designed and constructed for normal use on public roads but not for use on race courses or offroad terrain.

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 »

3

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 Supermoto. 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 »

4

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. .1
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . .	. .2
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . .	.6
Chassis number, Type label . . . . . . . . . . . . . . . . . . . . . . . .	.6
Engine number, engine type . . . . . . . . . . . . . . . . . . . . . . .	.6
OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . .	.7
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.7
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.7
Combined instrument . . . . . . . . . . . . . . . . . . . . . . . . . . .	.8
Function buttons on combined instrument . . . . . . . . . . . .	.8
Combined instrument display . . . . . . . . . . . . . . . . . . . . .	.8
Cooling liquid temperature display . . . . . . . . . . . . . . . . . .	12
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12
Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	13
Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	14
Immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	14
Securing vehicle after losing key . . . . . . . . . . . . . . . . . . . .	15
Reordering and programming keys . . . . . . . . . . . . . . . . . . .	15
Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	16
Emergency OFF tip switch, starter tip switch . . . . . . . . . . .	17
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	17
Fuel taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	17
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	17
Grips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	18
Seat lock, removing the seat . . . . . . . . . . . . . . . . . . . . . . .	18
Tool set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	19
Helmet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	19
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	19
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	20
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	20

Footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . .20
Compression damping of fork . . . . . . . . . . . . . . . . . .	. . . .21
Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . .	. . .21
Spring preload of the fork . . . . . . . . . . . . . . . . . . . . . .	. . .21
Damping action during compression of shock absorber	. . . .22
Rebound damping of shock absorber . . . . . . . . . . . . . .	. . .22
GENERAL TIPS AND WARNINGS FOR STARTING
THE MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . .23
Instructions for initial operation . . . . . . . . . . . . . . . . .	. . .23
Running in the LC8 engine . . . . . . . . . . . . . . . . . . . . .	. . .23
Accessories and payload . . . . . . . . . . . . . . . . . . . . . . .	. . .24
DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .	. . .25
Check the following before each start . . . . . . . . . . . . .	. . .25
Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . .	. . .27
Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . .28
Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . .28
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . .29
Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . . .	. . .30
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . .31
PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . .	. . .32
MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . .	. . .36
Adjusting the fork and shock absorber . . . . . . . . . . . .	. . .37
Adjusting compression damping of fork . . . . . . . . . . . .	. . .37
Adjusting rebound damping of fork . . . . . . . . . . . . . . .	. . .38
Adjusting the spring preload on the fork . . . . . . . . . . . .	. . .38
Compression damping of shock absorber . . . . . . . . . . .	. . .39
Rebound damping of shock absorber . . . . . . . . . . . . . .	. . .40
Breathing the fork legs . . . . . . . . . . . . . . . . . . . . . . .	. . .40
Checking the chain tension . . . . . . . . . . . . . . . . . . . .	. . .41
Correcting the chain tension . . . . . . . . . . . . . . . . . . .	. . .41

INDEX »

5

Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.42
Checking the chain for wear . . . . . . . . . . . . . . . . . . . . . . .	42
General information on KTM disk brakes . . . . . . . . . . . . . .	43
Changing the basic position of the handbrake lever . . . . . . .	45
Checking the front brake fluid level . . . . . . . . . . . . . . . . .	45
Checking the front brake pads . . . . . . . . . . . . . . . . . . . . .	46
Checking rear brake fluid level . . . . . . . . . . . . . . . . . . . . .	47
Checking the rear brake pads . . . . . . . . . . . . . . . . . . . . . .	47
Dismounting and remounting the front wheel . . . . . . . . . .	48
Dismounting and mounting the rear wheel . . . . . . . . . . . . .	50
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	52
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	53
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .	54
Jump start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	54
Main fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	55
Fuses for individual power consumers . . . . . . . . . . . . . . . .	56
Replacing the headlight lamp . . . . . . . . . . . . . . . . . . . . .	57
Adjusting the headlight range . . . . . . . . . . . . . . . . . . . . . .	58
Replacing the flasher bulbs . . . . . . . . . . . . . . . . . . . . . . .	58
Replacing the brake light and taillight bulbs . . . . . . . . . . .	59
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	60
Checking the cooling liquid level in the compensating tank . .	62
Checking the cooling liquid level in the radiator . . . . . . . . .	62
Bleeding the cooling system . . . . . . . . . . . . . . . . . . . . . . .	63
Changing the original position of the clutch lever . . . . . . . .	64
Checking the oil level of the hydraulic clutch . . . . . . . . . . .	64
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	66
Checking the engine oil level . . . . . . . . . . . . . . . . . . . . . .	66
Refilling engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	67

Changing the engine oil and the oil filter,

cleaning the oil screen . . . . . . . . . . . . . . . . . . . . . . . . . . .67 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 Indicator lamp blink code FI . . . . . . . . . . . . . . . . . . . . . . .73 Indicator lamp blink code immobilizer . . . . . . . . . . . . . . . .75 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 CONSERVATION FOR WINTER OPERATION . . . . . . . . . . . . . .77 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 TECHNICAL SPECIFICATIONS – CHASSIS . . . . . . . . . . . . . . .79 TECHNICAL SPECIFICATIONS – ENGINE . . . . . . . . . . . . . . .84 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

SERIAL NUMBER LOCATIONS »

6

Chassis number, Type label

The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1.

The type label is located next to the chassis number.

Engine number, engine type

The engine number and the engine type are stamped into the left side of the engine below the engine sprocket. Enter this number on page 1.

OPERATION INSTRUMENTS »

7

1	A

3

Clutch lever

The clutch lever [1] is fitted on the left hand side of the handle bar. 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 [3] is mounted on the right side of the handlebar.The basic position of the handbrake lever can be changed in 5 steps (see Maintenance work on chassis and engine).

OPERATION INSTRUMENTS »

8

1

2

Combined instrument

The combined instrument is divided into 4 parts.

Function buttons: to select the display modes and basic settings in the display

Tachometer:	displays the engine speed
Indicator lamps:	provide additional information on the motorcycle operating condition
Display:	shows the speed, cooling liquid temperature, time, ambient temperature,
	distance traveled (ODO), trip master 1 (TRIP 1), trip master 2 (TRIP 2),
	distance traveled since the reserve warning lamp went on (TRIP F)

Function buttons on combined instrument

MODE [1]

Briefly press the MODE button to go to the next display mode. The available display modes are ambient temperature, distance traveled (ODO), trip master 1 (TRIP 1) and trip master 2 (TRIP 2).

The speed, cooling liquid temperature and time are always displayed.

SET [2]

Press the SET button to reset trip master 1 or 2 to 0.

The 3rd button is not programmed.

Combined instrument display

TEST

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

LENGTH

The display will change for 1 second to display the circumference of the front wheel in millimeters. 1870 mm corresponds to a 17" front wheel.

Then the display will change back to the mode that was activated when the ignition was switched off.

	OPERATION INSTRUMENTS »				9
				SPEED [1]
				The speed can be displayed in kilometers per hour (km/h) or miles per hour (mph).
			1	CHANGING THE SPEED DISPLAY FROM KM/H - MPH or MPH - KM/H
				Switch on the ignition and press the MODE button more than 10 seconds in the ODO mode.

CLOCK [2]

The dots between the hours and minutes will blink in the CLOCK display.

The clock must be set if the battery was disconnected or if the fuse ACC1/CLOCK was blown.

SETTING THE CLOCK

Switch on the ignition and select the ODO mode. Press and hold the MODE button while you press the SET button more than 1 second. The time will start to blink.

Use the MODE button to set the hours. Use the SET button to set the minutes. Then press the MODE and SET buttons simultaneously.

2

AMBIENT TEMPERATURE [3]

The ambient temperature can be displayed in Celsius (°C) or Fahrenheit (°F).

CHANGING THE AMBIENT TEMPERATURE DISPLAY FROM °C - °F or °F - °C

Switch on the ignition and press the MODE button more than 10 seconds in the ambient temperature mode.

Press the MODE button to go to the next display mode.

3

OPERATION INSTRUMENTS »

10

FROST WARNING [1]

The frost symbol will start to blink regardless of the mode if the ambient temperature drops below 3°C (37.5°F).

1

ODO [2]

Displays the total kilometers or miles traveled.

This figure will not be cleared if the battery is disconnected.

2

	OPERATION INSTRUMENTS »		11
		TRIP 1 [1]
		The trip meter 1 is always active and counts up to 999.9. It is used to measure the length
		of the trip or the distance between 2 refueling stops.
		TO RESET TRIP 1
		To reset the trip meter 1 to zero, switch on the ignition, select the TRIP 1 display mode and
		press the SET button more than 2 seconds.
	1	Press the MODE button to go to the next display mode.
		TRIP 2 [2]
		The trip meter 2 is always active and counts up to 999.9. It is used just like TRIP 1.
		TO RESET TRIP 2
		To reset the trip meter 2 to zero, switch on the ignition, select the TRIP 2 display mode and
		press the SET button more than 2 seconds.
	2	Press the MODE button to go to the next display mode.
		TRIP F [3]
		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. 3 minutes for the fuel lamp to go out, TRIP F to auto-
		matically reset to 0 and to return to the previous display mode.
	3	NOTE:
		Press the SET button for 2 seconds to switch off the fuel warning lamp.

OPERATION INSTRUMENTS »

12

heiß/hot/caldo/chaud/caliente

normal normally

1 normalemente normalment normalmente

kalt / cold / freddo / froid / frío

Cooling liquid temperature display

The temperature display [1] is shown in 12 bars. The more bars that light up, the hotter the cooling liquid. 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 left radiator is not running

–Improper use of the clutch when driving slowly

			Tachometer
3
			The tachometer [3] shows the engine speed in revolutions per minute. Do not run the engine
			beyond the orange mark at 9500 rpm.
			The speed limiter will set in at 9600 rpm, drastically reducing the engine power above this
			rotational speed.

	OPERATION INSTRUMENTS »		13
		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 lamp 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).

The red warning lamp will light up if the voltage in the on-board electrics drops below 10 volts. Immediately drive to the nearest authorized KTM workshop and have the electrical system checked.

The red indicator lamp lights up briefly when the ignition is switched on and indicates that the immobilizer has been deactivated. When the ignition is switched off, the indicator lamp begins blinking after one minute with a 15-second interval to indicate that the immobilizer is activated. If the indicator lamp blinks rapidly, the system has detected a fault in the immobilizer. The fault can be identified by means of a blinking code (refer to Troubleshooting).

	OPERATION INSTRUMENTS »		14
		Ignition lock
		The ignition lock has 3 switching positions.
		Ignition off, (engine can't be started)
		Ignition on, light 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 .

NOTE:

Only the black ignition keys may be used (primary key or reserve key). The vehicle cannot be started with the orange master key - it can only be used for programming the immobilizer. Always keep the orange master key and the keycode card in a safe place!

Immobilizer

The immobilizer secures the vehicle against unauthorized use. When the ignition is switched off and the key is removed, the red indicator lamp [1] begins blinking after one minute with a 15-second interval to indicate that the immobilizer is activated. The starter, fuel supply and ignition system are now locked.

1

	OPERATION INSTRUMENTS »									15
								Securing vehicle after losing key
								A lost key can be blocked for this vehicle.
								LOSS OF PRIMARY KEY, RESERVE KEY AVAILABLE
								–	Switch on the ignition using the orange master key [2]. The red indicator lamp [1] lights
			1						up. Switch off the ignition.
								–	Switch on the ignition with the black reserve key [3]. The red indicator lamp [1] goes
									out for 0.5 seconds and then lights up again. Switch off the ignition.
								–	Switch on the ignition again with the orange master key [2]. The red indicator lamp [1]
									goes off for 3 seconds and then blinks according to the number of functioning keys includ-
									ing the master key – in this case, twice. Switch off the ignition.
								The lost key is now blocked. The reserve key remains functional.
		2			3			LOSS OF BOTH KEYS
								–	Switch on the ignition using the orange master key [2]. The red indicator lamp [1] lights
									up. Switch off the ignition.
								–	Switch the ignition on and off again using the orange master key [2].
								All keys for this vehicle are now blocked.
								Reordering and programming keys
								Every key that is to be used with this vehicle must be programmed first to be functional.
								–	Reorder key. The key number [4] is located on the key code card.
								–	Switch on the ignition using the orange master key [2]. The red indicator lamp [1] lights
			4						up. Switch off the ignition.
								–	Switch on the ignition with the black key [3]. The red indicator lamp [1] goes out for 0.5
									seconds and then lights up again. Switch off the ignition.
								–	Repeat this procedure with each additional key.
								–	Switch on the ignition again with the orange master key [2]. The red indicator lamp [1]
									goes off for 3 seconds and then blinks according to the number of functioning keys includ-
									ing the master key. Switch off the ignition.
								NOTE:
								A total of 4 keys can be programmed per vehicle.

OPERATION INSTRUMENTS »

16

2

1

1

3

4

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].

OPERATION INSTRUMENTS »

17

1

2

3

4

4

Emergency OFF tip switch, starter tip switch

The emergency off switch [1] 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 [2] to operate the electric starter.

Filler cap

The filler cap [3] can be locked and is provided with a fuel evaporation control system.

To open the cap insert the ignition key, turn it 90° counterclockwise, then lift off the filler cap.

To close the tank insert the filler cap, turn the ignition key 90° clockwise and take out the key.

Fuel taps

Both fuel taps [4] 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 tank.

	OPERATION INSTRUMENTS »				18
				Grips
	1
				The grips [1] are used to maneuver the motorcycle. If carrying a passenger, the passenger
				can hold on to the grip during the ride.
			1

3

4

5

Seat lock, removing the seat

The seat lock [3] can be locked with the ignition key.

To remove the seat, insert the ignition key and turn 45° in a counterclockwise direction. Lift the seat in the back, pull back and lift off.

		To mount, attach the seat to the two oval head screws [4], lower the rear and push forward
	6	at the same time. Both noses [5] should fit into the frame. Insert the catch bolts [6] in the
		lock housing and push the seat down in the back until you hear the catch bolts snap into
		place.
		Check whether the seat is correctly mounted.

If not correctly mounted, the seat can slip while you are driving and cause you to lose control of your motorcycle.

OPERATION INSTRUMENTS »

19

1

2

3

Tool set

The tool set [1] is located in the storage compartment under the seat.

Helmet lock

The steel rope [2] in the tool bag can be used to secure a helmet.

To secure, remove the seat, run the rope through the helmet, attach both ends to the hook [3] and mount the seat.

The helmet lock is provided to secure the helmet to the motorcycle when parked. Do not attach the helmet or other objects to the steel rope while driving. You can easily lose control of the motorcycle.

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.

2,3,4,5,6

N

1

OPERATION INSTRUMENTS »

20

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.

1

Foot brake pedal

The foot brake pedal [2] is located in front of the right footrest. Its basic position can be adjusted to your seat position (see maintenance work).

2

Footrests

The passenger footrests [3] fold up.

OPERATION INSTRUMENTS »

21

1

2

3

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 [1] are located on the fork leg axle passage.

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 [2] 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 [3].

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

OPERATION INSTRUMENTS »

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1

2

3

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.“

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 [3] is located on the bottom of the shock absorber.

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

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » 23

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 carefully before your first ride.

–Enter the chassis, engine and key numbers on page 1.

–Familiarize yourself with the operating elements.

–Adjust the hand brake lever and foot brake lever to your most comfortable position.

–This motorcycle is equipped with a threeway catalytic converter. 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.

–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 motorcycle and always use ORIGINAL KTM SPARE PARTS. Spare parts from other

manufacturers can impair the safety of the motorcycle.

–New wheels 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 (125 miles) 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 orange 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.

–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 » 24

–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.

–The tires must be designed for a speed of over 240 KPH (speed symbol ZR) and must be released by KTM.

–Wheels with a different rim diameter or other rim width may not be mounted otherwise the vehicle handling will no longer be safe.

–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

–Renew the vizor on your helmet on time so as to ensure optimum vision in any situation. When light shines directly on scratched visor, the operator will be blinded.

–A passenger may only ride on the motor-

cycle if passenger footrests are mounted.

–Never leave your motorcycle without supervision 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 motorcycle'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

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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:

1FUEL

Check the fuel quantity in the tanks.

2CHAIN

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.

3TIRES

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.

4BRAKES

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.

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5CABLES

Check the throttle cable for correct adjustment and smooth operation.

6COOLING FLUID

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

7ELECTRICAL SYSTEM

Start the engine and check the headlight, tail lamp, brake light, turn signals, indicator lamps, horn and emergency-off switch for proper functioning.

8CHECK OIL LEVEL

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

9BAGGAGE, PAYLOAD

Never exceed the maximum total weight (400 kg, 883 lbs) and the motorcycle's wheel loads. The maximum total weight is comprised of:

–the motorcycle in a running condition and refueled (205 kg, 452 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.

10 REAR MIRROR

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