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1. If the boundary between light and dark does not meet specifications Adjust the headlight range p 138 14 ELECTRICAL SYSTEM 14 9 Adjusting the headlight range Main work Remove expanding rivets O Remove screws O Lift the headlight mask slightly and swing forward 138 14 ELECTRICAL SYSTEM Adjust the beam distance of the headlight by turning screw O Guideline 139 headlight adjustment For a motorcycle with rider and with luggage and a passenger if applicable the light dark boundary must be exactly on the lower mark applied in Checking e Info Turn clockwise to increase the headlight range turn counterclockwise to reduce the headlight range Fold the headlight mask up Mount and tighten screws e Guideline Screw headlight mask M6 11 Nm 8 1 Ibf ft Loctite 243 Mount expanding rivets 1 on both sides 14 ELECTRICAL SYSTEM Finishing work Check the headlight setting p 137 140 15 COOLING SYSTEM 141 15 1 Cooling system 555550 Water pump 1 in the engine circulates the coolant The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap O Heat expansion causes excess coolant to flow into compensating tank O When the temperature falls this surplus coolant is sucked back into the cooling system This e
2. If the clutch lever play does not meet specifications Adjust the clutch cable play amp p 151 Note 00681 10 Clutch damage If there is no play on the clutch lever the clutch will begin to slip Before operating the motorcycle always check the clutch lever play Move the handlebar to and fro over the entire steering range The clutch lever play must not change 16 TUNING THE ENGINE 151 Ifthe clutch lever play changes Check the routing of the clutch cable 16 4 Adjusting the clutch cable play a Move the handlebar to the straight ahead position Push back sleeve O Loosen lock nut O Adjust the play in the clutch level A by turning adjusting screw O Guideline Clutch lever play 1 3 mm 0 04 0 12 in Tighten lock nut Position bellows O S00683 10 17 SERVICE WORK ON THE ENGINE 152 17 1 Checking the engine oil level 5550 Condition The engine is at operating temperature Preparatory work Stand the motorcycle upright on a horizontal surface Main work Check the engine oil level e Info After switching off the engine wait one minute before checking the level The engine oil must be between the markings o and o Ifthe engine oil is below the marking O Add the engine oil p 155 Ifthe engine oil is above the marking e Correct the engine oil level Warning
3. Tighten nuts e Tighten nut Guideline Make sure that chain adjusters o are fitted correctly on adjusting screws e Nut rear wheel spindle M14x1 5 90 Nm 66 4 Ibf ft 11 SERVICE WORK ON THE CHASSIS 88 Option With ABS Loosen nut O Loosen nuts e Adjust the chain tension by turning adjusting screws e on the left and right Guideline Chain tension 5 7 mm 0 2 0 28 in Turn adjusting screws e on the left and right so that the markings on the left and right chain adjusters o are in the same position relative to reference marks O The rear wheel is then correctly aligned Info e The upper chain section must be taut Chain wear is not always even so you should check the setting at different chain positions Tighten nuts O Make sure that chain adjusters o are fitted correctly on adjusting screws e Tighten nut Guideline Nut rear wheel spindle M14x1 5 90 Nm 66 4 Ibf ft Finishing work Take the motorcycle off of the rear wheel stand p 77 11 SERVICE WORK ON THE CHASSIS 11 13 Checking the chain rear sprocket and engine sprocket 100132 10 Check rear sprocket and engine sprocket for wear Ifthe rear sprocket or engine sprocket are worn Change the power set 4 e Info The engine sprocket rear sprocket and chain should only be changed together 89
4. 6 CONTROLS 54 The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears 401950 11 Foot brake lever is located in front of the right footrest The foot brake lever is used to activate the rear brake 402177 10 6 CONTROLS 55 N O 402029 10 The side stand O is on the left side of the vehicle The side stand is used to park the motorcycle e Info The side stand must be folded up during motorcycle use Side stand is coupled with the safety start system see the riding instructions Possible states e Side stand folded out The vehicle can be leaned on the side stand The safety start system is active e Side stand folded in This position is mandatory for all trips The safety start system is inactive 7 7 1 PREPARING FOR USE 56 Advice on first use Danger Danger of accidents Danger arising from the rider s judgement being impaired Do not operate the vehicle while under the influence of alcohol drugs and certain medications or physically or mentally impaired Warning Risk of injury Missing or poor protective clothing presents an increased safety risk Wear protective clothing helmet boots gloves pants and jacket with protectors every time you ride the vehicle Always wear protective clothing that is in good condition and meets the legal requirements Warn
5. e Info Do not operate the foot brake lever when the rear wheel is removed 13 WHEELS TIRES 113 Option With ABS Remove screw o and pull wheel speed sensor O out of the hole Remove nut e and washer Remove chain adjuster O Hold rear wheel and wheel spindle 5 pull out with washer and chain adjuster O Push the rear wheel forward as far as possible and take the chain off the rear sprocket Warning Danger of accidents Reduced braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not damaged Pull the rear wheel back and take it out of the swingarm e Info Do not operate the foot brake lever when the rear wheel is removed 13 4 Installing the rear wheel A Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary 13 WHEELS TIRES Warning 114 Danger of accidents No braking effect when operating the rear brake After installing the rear wheel always operate the foot brake until the pressure point is reached Main work Option Without ABS Check the rear hub rubber dampers 4 p 117 Check the wheel bearing for damage and wear Ifthe wheel bearing is damaged or worn Change the wheel bearing 4 Clean and grease the shaft seal rings 1 and matin
6. Screw rollover sensor M5 6 Nm 4 4 Ibf ft Loctite 243 Screw side stand switch M5 5 Nm 3 7 Ibf ft Loctite 243 Screw spoiler M5 5 Nm 3 7 Ibf ft Screw subframe cover bottom M5 5 Nm 3 7 Ibf ft Screw tail end lower part M5 6 Nm 4 4 Ibf ft Screw tail light M5 4 Nm 3 Ibf ft B Screw windshield M5 3 Nm 2 2 Ibf ft ABS module screw Option With ABS M6 8 Nm 5 9 Ibf ft Clutch cable retaining bracket screw M6 6 Nm 4 4 Ibf ft Damping rubber frame screw M6 7 Nm 5 2 Ibf ft Nut foot brake lever adjustment M6 9 Nm 6 6 Ibf ft Nut radiator M6 5 Nm 3 7 Ibf ft 21 TECHNICAL DATA 177 Remaining nuts chassis M6 10 Nm 7 4 Ibf ft Remaining screws chassis M6 10 Nm 7 4 Ibf ft Screw air filter box M6 6 Nm 4 4 Ibf ft Screw air filter box lid M6 3 Nm 2 2 Ibf ft Screw bottom of rear part M6 7 Nm 5 2 Ibf ft Screw brake fluid reservoir of rear brake M6 8 Nm 5 9 Ibf ft Screw cable holder side stand switch M6 9 Nm 6 6 Ibf ft Loctite 243 Screw chain sliding guard M6 9 Nm 6 6 Ibf ft Screw compensating tank M6 10 Nm 7 4 Ibf ft Screw foot brake cylinder M6 9 Nm 6 6 Ibf ft Loctite 2437 Screw front fender M6 9 Nm 6 6 Ibf ft Screw front seat fixing M6 6 Nm 4 4 Ibf ft Screw front spoiler M6 9 Nm 6 6 Ibf ft Screw fuel tank M6 1
7. Engine dies during the trip Lack of fuel Refuel p 71 Fuse 1 3 4 or 8 is blown Change the fuses of individual power consumers p 127 The ABS warning lamp lights up Option With ABS ABS fuse is blown Change the ABS fuses p 126 Large difference in wheel speeds of the front and rear wheels Stop the vehicle switch off the ignition and start it again Malfunction in ABS Read out the ABS fault memory using the KTM diagnostics tool 4 High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary Engine oil level too high Check the engine oil level 7 p 152 Engine oil too thin low viscosity Change the engine oil and oil filter clean the oil screen 4 p 152 Headlight and parking light are not Fuse 6 blown Change the fuses of individual power consumers functioning p 127 Turn signal brake light and horn are Fuse 6 blown Change the fuses of individual power consumers not functional 7 p 127 Time is not correctly displayed Fuse 2 blown Option Without ABS Change the fuses of individual power consumers p 127 Set the clock p 47 Fuse 8 blown Option With ABS Change the fuses of individual power consumers p 127 Set the clock p 47 20 TROUBLESHOOTING 165 Faults Battery discharged Possible cause
8. p 84 Check the tire condition p 118 Check the tire air pressure p 119 Check the settings of all controls and ensure that they can be operated smoothly Check the functioning of the electrical equipment Check that baggage is correctly secured Sit on the motorcycle and check the rear mirror setting Check the fuel level 8 RIDING INSTRUCTIONS 61 8 2 Starting Danger Al Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic components and safety equipment may be damaged Never operate the vehicle with a discharged battery or without a battery Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to increased wear Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always warm up the engine at low engine speeds 8 RIDING INSTRUCTIONS 62 OINGO B00782 10 Sit on the vehicle take the weight off of the side sta
9. Chassis number p 20 Type label p 20 O CO CO NI D om AJOI PM PM N NM Passenger footrests p 53 rA o Foot brake lever p 54 5 SERIAL NUMBERS se LO The chassis number O is stamped on the right side of the steering head As 402174 10 The type label is on the right of the frame behind the steering head 5 SERIAL NUMBERS 21 5 3 Enginemumber 000 The engine number is stamped on the left side of the engine under the engine sprocket 401949 10 The key number 1 can be found on the KEYCODECARD e Info You need the key number to order a spare key Keep the KEYCODECARD in a safe KEYCODECARD place 1234 O Kia 402245 10 6 CONTROLS 22 61 Chthlever 0 The clutch lever 1 is fitted on the left side of the handlebar S00656 10 The hand brake lever 1 is fitted on the right side of the handlebar The front brake is engaged using the hand brake lever S00663 10 6 CONTROLS 23 6 3 Throttle grip 0 The throttle grip is fitted on the right side of the handlebar S00664 10 The horn button 1 is fitted on the left side of the handlebar Possible states e Horn button in neutral position e Horn button pressed The horn is operated in this position S00660 10 6 CONTROLS 6 5 Light switch S00657 1
10. Clean threads of wheel spindle and axle nut Clean the fixing locations on the brake caliper support and swingarm 13 WHEELS TIRES 116 Install the rubber damper and rear sprocket carrier on the rear wheel Position the rear wheel Y The brake linings are correctly positioned Push the rear wheel as far forward as possible and place the chain on the rear sprocket Pull the rear wheel back and mount wheel spindle e with the washer and chain adjuster O Guideline Mount the left and right chain adjusters a in the same position Mount nut e and washer Push the rear wheel forward so that the chain adjusters are on the screws and tighten nut Guideline In order for the rear wheel to be correctly aligned the markings on the left and right chain adjusters must be in the same position relative to the reference marks O Nut rear wheel spindle M14x1 5 90 Nm 66 4 Ibf ft Position wheel speed sensor 5 in the drill hole Mount and tighten screw Q Guideline Screw wheel speed sensor holder M6 8 Nm 5 9 Ibf ft Finishing work Take the motorcycle off of the rear wheel stand p 77 Check the chain tension p 84 13 WHEELS TIRES 117 13 5 Checking the rear hub rubber dampers A e Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers They eve
11. OWNER S MANUAL 2015 125 Duke EU 200 Duke EU 200 Duke AR 200 Duke ASIA 200 Duke BR 200 Duke CN 200 Duke MY Art no 3213278en Ux e Si 2 DEAR KTM CUSTOMER 1 Congratulations on your decision to purchase a KTM motorcycle You are now the owner of a state of the art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly We wish you a lot of enjoyment in riding this vehicle Enter the serial numbers of your vehicle below Chassis number p 20 Dealer s stamp Engine number p 21 Key number p 21 The Owner s Manual contained the latest information for this model series at the time of going to print Minor differences due to develop ments in design cannot be ruled out completely All specifications 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 devi ations from illustrations and descriptions misprints and other errors The models portrayed partly contain special equipment that does not belong to the regular scope of supply 2015 KTM Sportmotorcycle GmbH Mattighofen Austria All rights reserved
12. Screw chain guard EJOT PT 4 Nm 3 Ibf ft Tighten screw Guideline Remaining screws chassis M5 5 Nm 3 7 Ibf ft 11 SERVICE WORK ON THE CHASSIS 93 Remove screws O B00770 10 Remove screws O Take off the front spoiler gt My A 11 SERVICE WORK ON THE CHASSIS 94 B00770 10 A gt LI F hl Position the front spoiler Mount screws 1 but do not tighten yet Mount and tighten screws e Guideline Screw front spoiler M6 9 Nm 6 6 Ibf ft Tighten screw O Guideline Screw front spoiler M6 9 Nm 6 6 Ibf ft 12 BRAKE SYSTEM 95 12 1 ABS antilock brake system Option With ABS 401687 10 The ABS unit O which consists of a hydraulic unit ABS control unit and return pump is installed under the seat A wheel speed sensor 2 is located at the front and rear wheels Warning Danger of accidents Functional limitations of the ABS The rear wheel may only be spun with the front brake applied burn out if the ABS is switched off If the vehicle has been modified such as shortened or lengthened spring deflec tions different rim diameters different tires the wrong tire air pressure differ ent brake linings etc the ABS will not function optimally Optimal function ing of the ABS is only ensured if the brake system only contains spare parts and tires
13. Status or error message for immobilizer alarm system OPTIONAL DOGODIO The general warning lamp lights up yellow An operating safety warning message was detected This is also shown in the info display Option With ABS E ABS warning lamp lights up flashes yellow Status or error messages relating to ABS antilock brake system 6 CONTROLS 6 13 6 Display 401685 11 35 The speed o is shown in kilometers per hour km h or in miles per hour mph The tachometer e shows the engine speed in revolutions per minute The gear display e shows the engaged gear The coolant temperature appears in segment O The time appears in segment O The filling level in the fuel tank is displaced in segment O The info display O shows additional information e Info The time must be reset after the battery was disconnected or the fuse was removed The intensity of the LED display depends on the ambient brightness 6 CONTROLS 6 13 7 Filling level display in fuel tank 401292 01 36 The filling level display consists of 9 bars The more bars are lit the more fuel is in the fuel tank 6 CONTROLS 6 13 8 TRIP F display 401293 01 37 If the fuel level drops to the reserve mark the display mode automatically changes to TRIP F and starts to count from 0 0 regardless of the previous display mode e Info At the same time as the display mode TRIP
14. properly at regular intervals Warning Danger of accidents Changed handling characteristics and longer stopping distance with excessive payload Adapt your speed according to your payload Warning Danger of accidents Unstable handling characteristics due to slipped baggage Check the way your baggage is fixed regularly 7 PREPARING FOR USE 59 If you carry any baggage make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu tion between the front and rear wheels Do not exceed the overall maximum permitted weight and the axle loads Guideline Maximum permissible overall weight 335 kg 739 Ib Maximum permissible front axle load 125 kg 276 Ib Maximum permissible rear axle load 210 kg 463 Ib 8 RIDING INSTRUCTIONS 8 1 Checks and maintenance when preparing for use e Info Before every trip check the condition of the vehicle and ensure that it is roadworthy The vehicle must be in perfect technical condition when used Check the engine oil level p 152 Check the brake fluid level of the front brake p 97 Check the rear brake fluid level 7 p 102 Check the front brake linings 7 p 99 Check the rear brake linings p 105 Check the brake system function Check the coolant level p 144 Check for chain dirt accumulation p 83 Check the chain tension
15. 11 SERVICE WORK ON THE CHASSIS Shift gear to neutral 90 Pull the lower chain section with specified weight O Guideline Weight chain wear measurement 15 kg 33 Ib Measure the distance o of 20 chain links in the lower chain section 18 19 20 401288 10 e Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance o at the longest chain section 301 6 mm 11 874 in f distance eo is greater than the specified measurement Change the power set 4 Info e When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out faster on old worn sprockets 11 SERVICE WORK ON THE CHASSIS Remove screw O 2 and Push the chain guard aside Check the chain sliding guard for wear Ifthe chain sliding guard has lost material due to wear to the extent that in area O drilled hole is visible from above Change the chain sliding guard 4 Check that the chain sliding guard is firmly seated Ifthe chain sliding guard is loose A td A Tighten the screws on the chain sliding guard ASA 11 SERVICE WORK ON THE CHASSIS 92 gt m Position the chain guard and tighten screw Guideline Screw chain guard EJOT PT 4 Nm 3 Ibf ft Tighten screw O Guideline
16. Baesage oci x b sl eau a eus en A ss 58 Battery installing m x ut deste tat stents e aad ne den taal CR 122 recharging a Susa ebd y n di Wall ERREUR SES 123 relmoVifig a veste Sut wae that e ARGENTEOS RUD 121 Brake discs GheCKING A Veo site cani sos bald d h Xin b bed ae en ole 96 Brake fluid front brake adding KK KI K K K K KI K K KIR KIIR 98 rear brake adding XI KIR RIK RIK KIR oo 104 Brake fluid level front brake checking kk kK KI RIK K KI KIRI KI eee 97 rear brake checking 0 0 00 KIRR K K KII KK 102 Brake linings front brake checking kk KK KIRR KK KIRI K K eee 99 rear brake checking kk kK K R KIRI KII KK 105 DL SEN nd a N gt N NIM YA y 66 187 Brakes applying 0 00 0 ccc RR RIK KI KI 66 C Capacity COOLANT ait d eau o wr Siar Saleen Tae gates 172 engine oll iss ess lll ke a ee ees 155 171 f el i21 dde vA iro v ser ade due 72 172 Chain chain dirt accumulation checking 83 CHECKING Lucia a HH HH HHHH oro AS Da 89 cleanings at a E se Stans 83 Chain tension adJ stlng 2 2 2 suna RA oe eke sakes 86 Checking codicia BA aya Wa en d la eae m l 84 Chassis number A kk KK KK KK KI KI KI KIR KI KIR KIR KIRI KI KIR 20 Clutch cable play adjusting 4 oen Ban s s und toe nd du eR alae lt 151 Gl tch lever iom RR ei cee 22 Clutch lever play Checking eui er e DAVA nad Poi B
17. C 13 49 F Ifthe antifreeze in the coolant does not match the specified value Correct the coolant antifreeze Check the coolant level in the compensating tank The coolant level must be between MIN and MAX If the coolant level does not match the specified value Correct the coolant level Coolant p 181 Mount the cap of the compensating tank 15 COOLING SYSTEM 144 Remove radiator cap O Check the coolant antifreeze 25 45 C 13 49 F If the antifreeze in the coolant does not match the specified value Correct the coolant antifreeze Check the coolant level in the radiator AA The radiator must be completely filled y j B01552 10 If the coolant level does not match the specified value Correct the coolant level and find out the cause of the loss Coolant p 181 f you had to add more coolant than the specified amount gt 0 201 gt 0 21 qt Fill bleed the cooling system 4 p 147 Mount the radiator cap LA Warning E A Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water 15 COOLING SY
18. Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations 17 SERVICE WORK ON THE ENGINE 153 e Info Drain the engine oil only when the engine is warm Preparatory work Remove the front spoiler p 93 Stand the motorcycle on its side stand on a horizontal surface Main work Place a suitable container under the engine Remove the oil drain plug 1 with the O ring Remove oil screen with the O ring Completely drain the engine oil Clean the oil drain plug and oil screen thoroughly ay Position oil screen and mount and tighten oil drain plug with the O ring Guideline S00684 10 Oil drain plug 125 Duke M24x1 5 15 Nm 11 1 Ibf ft Oil drain plug 200 Duke M24x1 5 15 Nm 11 1 Ibf ft 17 SERVICE WORK ON THE ENGINE 154 Remove screws O Remove the oil filter cover o with the O ring Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing area Insert oil filter O Oil the O
19. F the general warning lamp lights up and the warning note Low Fuel Level appears on the info display 6 CONTROLS 6 13 9 Coolant temperature indicator The temperature display consists of 13 bars The more bars that light up the hotter the coolant When all bars light up the following warning note appears on the info display High Coolant Temperature Possible states e Engine cold Up to three bars light up e Engine warm Four to ten bars light up e Engine hot Eleven to thirteen bars light up 401292 01 6 CONTROLS 6 13 10 Info display 401291 10 Various warning notes appear on info display O If the general warning lamp lights up the corresponding warning note is shown on the info display 39 6 CONTROLS 40 6 13 11 Riding time average speed menu Condition Alternative 1 e The ignition is on e The motorcycle is stationary Alternative 2 e The ignition is on e The motorcycle is moving Press the SET button briefly and repeatedly until the desired info display appears The riding time and average speed are displayed in this menu e Info If the ignition was switched off for over 60 minutes the display is reset to O Press the SET button Next display mode on the info display briefly 6 13 12 Average speed average fuel consumption 1 menu Condition Alternative 1 The ignition is on e The motorcycle is stationary Alternative 2
20. Ibf ft Screw front brake disc M8 30 Nm 22 1 Ibf ft Loctite 243 Screw front wheel spindle M8 26 Nm 19 2 Ibf ft Screw handlebar clamp M8 21 Nm 15 5 Ibf ft Loctite 2437 Screw handrail M8 30 Nm 22 1 Ibf ft Screw horn M8 7 Nm 5 2 Ibf ft Screw main silencer M8 24 Nm 17 7 Ibf ft Screw passenger footrest bracket M8 26 Nm 19 2 Ibf ft Loctite 2437 Screw rear brake disc M8 30 Nm 22 1 Ibf ft Loctite 243 Screw shift lever M8 16 Nm 11 8 Ibf ft Loctite 243 Screw top triple clamp M8 15 Nm 11 1 Ibf ft 21 TECHNICAL DATA 179 Screw front brake caliper M8x1 30 Nm 22 1 Ibf ft Loctite 2047 Banjo bolt brake line M10 24 Nm 17 7 Ibf ft Fitting side stand M10 35 Nm 25 8 Ibf ft Loctite 2437 Nut mirror image left M10 20 Nm 14 8 Ibf ft Remaining nuts chassis M1O 45 Nm 33 2 Ibf ft Remaining screws chassis M10 45 Nm 33 2 Ibf ft Screw engine bearer on engine M10 47 Nm 34 7 Ibf ft Fitting bottom shock absorber M10x1 25 45 Nm 33 2 Ibf ft Fitting handlebar support M10x1 25 21 Nm 15 5 Ibf ft Nut mirror image right M10LHx1 25 20 Nm 14 8 Ibf ft Nut rear sprocket screw M10x1 25 27 Nm 19 9 Ibf ft Loctite 243 Nut turn signal M10x1 25 6 Nm 4 4 Ibf ft Screw front footrest bracket M10x1 25 47 Nm 34 7 Ibf ft Loctite 243 Screw front footrest bracket engine
21. SCHEDULE 9 1 Service schedule 73 Every four years Every 15 000 km 9 321 mi or every 2 years Every 7 500 km 4 660 mi or annually Once after 1 000 km 621 4 mi Check the functioning of the electrical equipment o e e Read out the fault memory using the KTM diagnostics tool O Change the engine oil and oil filter clean the oil screen amp p 152 O Check the brake discs p 96 o e e Check the front brake linings p 99 o e Check the rear brake linings p 105 o e e Check the tire condition p 118 O e o Check the tire air pressure p 119 o e Check the brake lines for damage and leakage O e o Check the brake fluid level of the front brake p 97 O e E Check the rear brake fluid level p 102 o e e Check the shock absorber and fork for leaks O e e Clean the dust boots of the fork legs o Check the chain rear sprocket and engine sprocket p 89 Check the chain tension p 84 o e e Check the coolant level p 144 o e e Check the antifreeze O e e Change the coolant Check that the radiator fan is functioning properly A o e e 9 SERVICE SCHEDULE 74 Every four years Every 15 000 km 9 321 mi or every 2 years Every 7 500 km 4 660 mi or annually Once after 1 000 km 621 4 mi Change the air filter Clean the air filter box 4
22. The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Mount the supports of the wheel stand Insert the adapter in the rear wheel stand Bushing kit for lifting gear 90229955044 Universal V adapter 61029955244 Rear wheel stand 61029055400 Stand the motorcycle upright align the lifting gear with the swingarm and the adapters and lift the motorcycle 00682 01 11 2 Taking the motorcycle off of the rear wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 11 SERVICE WORK ON THE CHASSIS Secure the motorcycle against falling over DO TIO 402029 10 11 3 Raising the motorcycle with the front wheel stand Remove the rear wheel stand and lean the vehicle on the side stand O 78 Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Preparatory work Raise the motorcycle with the rear wheel stand p 77 Condition Remove protection cap O M00005 10 11 SERVICE WORK ON THE CHASSIS Move the handlebar to the straight ahead position Position the wheel stand 79 Adapter 61029955620 Front wheel stand 61029055500 e Info Always raise the rear of the motorcycle first C001
23. and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution A Indicates a danger that may lead to minor injuries if the appropriate measures are not taken Note Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken Warning xt Indicates a danger that will lead to environmental damage if the appropriate measures are not taken 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 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 pur chaser 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 2 SAFETY ADVICE 11 1 Removal or puncturing of the main silencer baffles header pipes or any other components which conduct exhaust gases 2 Removal or puncturing of parts of the intake system 3 Lack of proper maintenance 4 Replacing moving part of the vehicle or
24. cared for by specially trained experts using the specialist 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 1 MEANS OF REPRESENTATION 8 The typographical formats used in this document are explained below Specific name Identifies a proprietary name Name Identifies a protected name Brand Identifies a brand available on the open market Underlined terms Refer to technical details of the vehicle or indicate technical terms that are explained in the glossary 2 SAFETY ADVICE 9 2 1 Use definition KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race courses or offroad e Info The motorcycle is authorized for public road traffic in the homologous version only A number of safety instructions need to be followed to operate the vehicle safely Therefore read this manual carefully The safety instruc tions are highlighted in the text and are referred to at the relevant passages e info The vehicle has various information and warning labels at prominent locations Do not remove information warning labels If they are missing you or others may not recognize dangers and may therefore be injured 2 SAFETY ADVICE 10 2 3 Degrees of risk and symbols 000 Danger Al Indicates a danger that will immediately
25. e e Check that the throttle cables are undamaged routed without sharp bends and set correctly 4 o e e Grease all moving parts e g side stand hand lever chain and check for smooth operation amp o e e Check all hoses e g fuel cooling bleeder drainage etc and bellows for cracking leaks and correct routing 4 o e e Check the cables for damage and routing without sharp bends 4 e o Change the spark plugs 4 e Check the valve clearance 4 o o Change the front brake fluid 4 Change the rear brake fluid A Check the swingarm bearing amp Check the wheel bearing for play A Check the steering head bearing play O e Check the screws and nuts for tightness 4 O Check the headlight setting p 137 o ee e Final check Check the vehicle for roadworthiness and take a test ride O Read out the fault memory using the KTM diagnostics tool after a test ride O Reset the service interval display 4 O Make the service entry in the KTM Dealer net and in the Service and Warranty Booklet 4 O o One time interval e Periodic interval 10 TUNING THE CHASSIS 75 10 1 Adjusting the spring preload of the shock absorber A Warning A Danger of accidents Modifications to the suspension settings can seriously alter the vehicle s ride behavior Following modifications ride slowly at first to get the feel of the new ride behavior Info The spring preload defines the initial s
26. forth to ascertain play O in the throttle cable Throttle cable play 3 5 mm 0 12 0 2 in Ifthe throttle cable play does not meet specifications Adjust the play in the throttle cable 4 p 150 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and let it run idle Move the handlebar to and fro over the entire steer ing range The idle speed must not change If the idle speed changes Check the throttle cable routing 16 TUNING THE ENGINE 150 16 2 Adjusting the play in the throttle cable a Move the handlebar to the straight ahead position Push back sleeve O Loosen lock nut O Adjust the play in the throttle cable by turning adjusting screw e Guideline Throttle cable play 3 5 mm 0 12 0 2 in Tighten lock nut O M00731 10 Slide on sleeve O 16 3 Checking the clutch lever play Check the clutch lever for smooth operation o 4 Move the handlebar to the straight ahead position Pull the clutch lever until resistance IN is perceptible and determine the play in the clutch lever O Clutch lever play 1 3 mm 0 04 0 12 in
27. front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Preparatory work Check the front brake linings p 99 12 BRAKE SYSTEM 99 Main work Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws O Remove cover e with membrane O Add brake fluid to level Guideline Level 5 mm 0 2 in C00201 10 Brake fluid DOT 4 DOT 5 1 p 181 Position the cover with the membrane Mount and tighten the screws e Info Clean up overflowed or spilt brake fluid immediately with water 12 5 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help Note Danger of accidents Reduced braking efficiency caused by damaged brake discs Ifthe brake linings are not changed in time the steel brake lining carriers grind on the brake disc The braking effect is greatly reduced and the brake
28. gt cs Kn KURKA AN N aa NM ee A ES 21 Engine oil adding 188 changing 2 4 ne dna REGIS ESSA RA 152 Engine oil level CHECKING cre bee med m 152 Engine sprocket GHeECKING z 2525 E ate ERU C Ei E RE 89 Environment ao oo 12 F FIgures ou DD er ee HHH HH 15 Filler cap ClOSING 44 da dn AL lg Anan cet oan ir Shh de oe GAVA aed 51 Opening sc ac dede Ra rede Ss 49 Filling up A ex dea s SS E Saal pA Ed UE SUE rea 71 Foot brake lever uomen UR ab da W K ues 54 free travel adjusting o o ooo KI KIRI KI KI KIRI KI oo 101 free travel checking o oooooooooooooooo o 100 Front spoiler installing 5 4 45 54 Seda ee RIT E a qeday 94 OVINA A Pee Be et we 93 Front wheel installing e scan Ga kya is na te sd En 108 rEMOVINS sz S mend bn uisus os aa o Sad 107 Fuse individual power consumers changing 127 Fuses ABS Changing se dole hen be eid m IS 126 INDEX Grab handles so est bae ka e MA h dk 52 Hand brake lever 0 002 ee 22 Headlight adjustment adjusting Sauer b Qa m S de ace eer Balan ss 138 CHECKING za s ar Puce Role A ARR Re Gen Hd 137 Headlight bulb Changing ium ad M 131 High beam flasher button o oo 24 Hoin button che suck eee ae ee RR ies 23 Ignition lock llle 26 Indicator lamps llle 34 Key n mber wing fan Seated pma ERR S 21 Kilometers or miles adj stlhg usa s et A ol alarak RO UHR o
29. in tempera ture e Info KTM recommends jacking up the motorcycle Raise the motorcycle with the rear wheel stand p 77 19 STORAGE 19 2 Preparing for use after storage LE ae N 401059 01 162 Raise the motorcycle with the front wheel stand p 78 Cover the motorcycle with a tarp or similar cover that is permeable to air Info e Do not use non porous materials since they prevent humidity from escaping thus causing corrosion Avoid running the engine for a short time only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust Take the motorcycle off of the front wheel stand p 79 Take the motorcycle off of the rear wheel stand p 77 Install the battery 4 p 122 Set the clock p 47 Perform checks and maintenance steps when preparing for use p 60 Take a test ride 20 TROUBLESHOOTING 163 Faults Engine does not crank when the elec tric starter button is pressed Possible cause Operating error Action Go through the steps of starting the engine p 61 Battery discharged Recharge the battery 4 p 123 Fuse 1 3 4 or 8 is blown Change the fuses of individual power consumers p 127 No ground connection present Check the ground connection Engine turns
30. metal parts except for brake discs and exhaust system with anti corrosion materials Preserving materials for paints metal and rubber p 185 Treat all painted parts with a mild paint polish 18 CLEANING CARE 159 Perfect Finish and high gloss polish for paints p 185 e Info Do not polish parts that were matte when delivered as this would strongly impair the material quality Treat all plastic parts and powder coated parts with a mild cleaning and care product Special cleaner for glossy and matte paint finishes metal and plastic surfaces p 185 Oil the ignition steering lock Universal oil spray 7 p 185 18 2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter salt can be expected on the roads Precautions need to be taken against road salt corrosion If the vehicle was operated in road salt clean it with cold water after riding Warm water would enhance the corrosive effects of salt E E O dE LS Oy MAS EN m 3 e 401060 01 Clean the motorcycle p 157 Clean the brakes e Info l After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts are cooled down and while they are installed After riding on salted roads thoroughly wash the mo
31. only if the clutch lever is drawn The vehicle is in gear Shift gear to neutral The vehicle is in gear and the side stand is folded out Shift gear to neutral Engine turns but does not start Operating error Go through the steps of starting the engine p 61 Fault in fuel injection system Read out the fault memory using the KTM diag nostics tool A Engine has too little power Air filter is very dirty Change the air filter Fuel filter is very dirty Check the fuel pressure 4 Fault in fuel injection system Read out the fault memory using the KTM diag nostics tool Engine overheats Too little coolant in cooling system Check the cooling system for leakage Check the coolant level 7 p 144 Radiator fins very dirty Clean the radiator fins Foam formation in cooling system Drain the coolant 4 p 146 Fill bleed the cooling system amp p 147 Thermostat defective Check the thermostat 4 Fuse 5 blown Change the fuses of individual power consumers p 127 20 TROUBLESHOOTING 164 Faults Engine overheats Possible cause Defect in radiator fan system Action Check the radiator fan system 4 The engine diagnosis warning lamp MIL lights up red Fault in fuel injection system Read out the fault memory using the KTM diag nostics tool A
32. specifications 12 BRAKE SYSTEM 102 Disconnect spring O Release nut 2 and use screw to adjust the specified free travel O Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in e Info The range of adjustment is limited Hold screw e and tighten nut e Attach spring O je OSS PAN 12 8 Checking the rear brake fluid level Warning Danger of accidents Failure of the brake system Ifthe brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help 12 BRAKE SYSTEM 103 Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Option Without ABS Stand the vehicle upright Check the brake fluid level in the brake fluid reservoir If the fluid level reaches the MIN marking Add rear brake fluid 4 p 104 Option With ABS Stand the vehicle upright Check the brake fluid level in the brake fluid reservoir If the fluid level reaches the MIN marking Add rear brake fluid 4 p 104 12 12 9 BRAKE SYSTEM 104 Adding rear brake fluid 4 A A A Warning Danger of accidents Failure of
33. that the tires are changed regardless of the actual wear at the latest after 5 years Ifa tire is more than 5 years old Change the tires e Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life 13 WHEELS TIRES 400695 01 Remove the dust cap Check tire air pressure when the tires are cold 120 Tire air pressure solo Front 2 0 bar 29 psi Rear 2 0 bar 29 psi Tire air pressure with passenger full payload Front 2 0 bar 29 psi Rear 2 2 bar 32 psi If the tire air pressure does not meet specifications Correct the tire air pressure Mount the dust cap 14 ELECTRICAL SYSTEM 121 1 Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Preparatory work Remove the passenger seat p 80 Remove the seat p 81 Main work Pull back the negative t
34. the brake system Ifthe brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles f brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Preparatory work Check the rear brake linings 7 p 105 12 BRAKE SYSTEM 105 Main work Option Without ABS Stand the vehicle upright Remove screw cap with membrane Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 181 Refit scre
35. the chain tension p 86 11 SERVICE WORK ON THE CHASSIS 86 11 12 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain is too taut the components of the secondary power transmission chain engine sprocket rear sprocket bearings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme cases If the chain is too loose however it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine Ensure that the chain tension is correct and adjust it if necessary Preparatory work Check the chain tension p 84 Raise the motorcycle with the rear wheel stand p 77 11 SERVICE WORK ON THE CHASSIS Main work Option Without ABS Loosen nut O Loosen nuts O Guideline 87 Adjust the chain tension by turning adjusting screws e on the left and right Chain tension 5 7 mm 0 2 0 28 in Turn adjusting screws e on the left and right so that the markings on the left and right chain adjusters o are in the same position relative to reference marks O The rear wheel is then correctly aligned Info chain positions e The upper chain section must be taut Chain wear is not always even so you should check the setting at different
36. the vehicle while the engine is running Secure the vehicle against use by unauthorized persons If you leave the vehicle lock the steering and remove the ignition key Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch hot components such as exhaust system radiator engine shock absorber and the brake system Allow these components to cool down before starting work on them Danger of damage The parked vehicle may roll away or fall over 8 RIDING INSTRUCTIONS 69 Always place the vehicle on a firm and even surface Note Fire hazard Some vehicle components become very hot when the vehicle is operated Do not park the vehicle near flammable or explosive substances Do not place objects on the vehicle while it is still warm from being run Always let the vehicle cool first Note Material damage Damage to or destruction of components due to excessive load The side stand is only designed for the weight of the motorcycle Do no sit on the motorcycle when it is resting on the side stand The side stand or the frame may become damaged and the motorcycle may fall over Brake the motorcycle Shift gear to neutral Switch off the ignition by turning the ignition key to the position amp e Info If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock power continues to flow to most power con
37. third fuse which protects the ABS control unit is located in the fuse box Preparatory work Switch off all power consumers and the engine Remove the passenger seat p 80 To change the fuse of the ABS hydraulic unit Take off the protection cap and remove fuse O e Info A defective fuse is indicated by a burned out fuse wire O 0 Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never bypass or repair fuses Use spare fuses with the correct rating only Fuse 75011088015 p 174 14 ELECTRICAL SYSTEM 127 e Tip Replace spare fuse e in the fuse box so that it is available if needed Mount the protection cap To change the fuse of the ABS return pump Take off the protection cap and remove fuse e Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never bypass or repair fuses Use spare fuses with the correct rating only Fuse 90111088025 p 174 e Tip Replace spare fuse o in the fuse box so that it is available if needed Mount the protection cap Finishing work Mount the passenger seat p 81 14 5 Changing the fuses of individual power consumers e Iinfo The fuse box with the main fuse and the fuses of the i
38. your feet on the footrests when riding Run the engine in p 57 7 2 Running in the engine During the running in phase do not exceed the specified engine speed Guideline Maximum engine speed During the first 1 000 km 620 mi 7 500 rpm e Tip During the running in phase set the shift warning light to the specified engine speed Adjust the shift speed RPM 1 p 48 Adjust the shift speed RPM 2 p 48 Avoid fully opening the throttle 7 7 3 PREPARING FOR USE 58 Loading the vehicle Warning Danger of accidents Unstable handling characteristics Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational and with a full tank driver and passenger with protective clothing and helmet baggage Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and or tank rucksack Mount and secure suitcase and tank rucksack according to the manufacturer s instructions Warning Danger of accidents Risk of breakage of suitcase system f you have fitted suitcases on your motorcycle read the manufacturer s specifications concerning the maximum payload Warning Danger of accidents Poor visibility for other road users due to slipped baggage Ifthe tail light is covered you are less visible to traffic behind you especially when it is dark Check that your baggage is fixed
39. 0 6 6 High beam flasher button S00659 10 The light switch 1 is fitted on the left side of the handlebar Possible states 24 z Low beam on The light switch is turned downward In this position the z low beam and the tail light are switched on High beam on The light switch is turned upwards In this position the D high beam and the tail light are switched on The high beam flasher button 1 is fitted on the left side of the handlebar Possible states e High beam flasher button in neutral position e High beam flasher button pressed In this position the headlight flasher high beam is actuated 6 CONTROLS 6 7 Turn signal switch 00658 10 6 8 Emergency OFF switch 00661 10 25 The turn signal switch o is fitted on the left side of the handlebar Possible states Turn signal off Turn signal left on Turn signal switch pressed to the left The turn signal a switch returns automatically to the central position after use Turn signal right on Turn signal switch pressed to the right The turn signal switch returns automatically to the central position after use To switch off the turn signal press the turn signal switch towards the switch case The emergency OFF switch O is fitted on the right side of the handlebar Possible states Emergency OFF switch off In this position the ignition circuit is
40. 0 Nm 7 4 Ibf ft Screw headlight holder M6 9 Nm 6 6 Ibf ft Screw headlight mask M6 11 Nm 8 1 Ibf ft Loctite 2437 Screw ignition coil M6 9 Nm 6 6 Ibf ft Screw license plate holder M6 12 Nm 8 9 Ibf ft Loctite 2437 Screw magnetic holder on side stand M6 5 Nm 3 7 Ibf ft Loctite 243 Screw main silencer M6 10 Nm 7 4 Ibf ft Screw radiator bracket M6 6 Nm 4 4 Ibf ft Screw radiator holder M6 8 Nm 5 9 Ibf ft Screw rear ABS sensor wheel Option M6 7 Nm 5 2 Ibf ft Loctite 243 With ABS Screw rear splash protector M6 9 Nm 6 6 Ibf ft 21 TECHNICAL DATA 178 Screw rollover sensor holder M6 10 Nm 7 4 Ibf ft Screw seat M6 10 Nm 7 4 Ibf ft Screw shift lever linkage M6 11 Nm 8 1 Ibf ft Loctite 243 Screw voltage regulator M6 11 Nm 8 1 Ibf ft Screw voltage regulator holder M6 11 Nm 8 1 Ibf ft Screw wheel speed sensor holder M6 8 Nm 5 9 Ibf ft Option With ABS Silent block retaining bracket screw M6 7 Nm 5 2 Ibf ft Fitting engine mounting bracket M8 48 Nm 35 4 Ibf ft Remaining nuts chassis M8 25 Nm 18 4 Ibf ft Remaining screws chassis M8 25 Nm 18 4 Ibf ft Screw bottom triple clamp M8 15 Nm 11 1 Ibf ft Screw engine bearer on frame M8 26 Nm 19 2 Ibf ft Screw foot brake lever M8 16 Nm 11 8 Ibf ft Loctite 243 Screw fork stub M8 15 Nm 11 1
41. 031 0 0047 in Valve clearance exhaust cold 0 13 0 17 mm 0 0051 0 0067 in Crankshaft bearing Two ball bearings Conrod bearing Sleeve bearing Pistons Cast light alloy Piston rings 1 compression ring 1 tapered compression piston ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with one rotary pump Primary transmission 22 72 Clutch Clutch in oil bath mechanically activated Transmission 6 gear claw shifted Transmission ratio 1st gear 12 34 2nd gear 15 31 3rd gear 18 28 4th gear 21 26 bth gear 22 23 6th gear 24 22 Mixture preparation Electronically controlled fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12V 230 W Spark plug BOSCH VR 5 NE Spark plug electrode gap 0 8 mm 0 031 in 21 TECHNICAL DATA 169 Spark plug BOSCH Super R6 VR 5 NEW Spark plug electrode gap 1 mm 0 04 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 450 1 550 rpm Starting aid Electric starter 21 2 Engine tightening torques Oil nozzle M5 6 Nm 4 4 Ibf ft Loctite 2437 Screw engine vent plate M5 7 Nm 5 2 Ibf ft Loctite 2437 Screw oil filter cover M5 8 Nm 5 9 Ibf ft Screw re
42. 13 14 Average fuel consumption 2 service menu Condition Alternative 1 e The ignition is on e The motorcycle is stationary Alternative 2 e The ignition is on e The motorcycle is moving Press the SET button briefly and repeatedly until the desired info display appears The average fuel consumption 2 in km L or miles L and the distance to the next service are displayed in this menu e Info The average fuel consumption 2 is displayed after several 100 meters of travel after the ignition is switched on If the ignition was switched off for over 60 minutes the display of the average fuel consumption 2 is reset to O Press the SET button Next display mode on the info display briefly 6 CONTROLS 43 6 13 15 Service range menu Condition Alternative 1 e The ignition is on e The motorcycle is stationary Alternative 2 e The ignition is on e The motorcycle is moving Press the SET button briefly and repeatedly until the desired info display appears This menu shows the distance to the next service and the range e Info The range depends on the average fuel consumption and the fuel quantity in the fuel tank The range is displayed after several 100 meters of travel after the ignition is switched on If the ignition was switched off for over 60 minutes the display of the range and riding time is reset to O Press the SET button Next display mode on the info di
43. 32 Service Not Reset appears on the info display for 10 seconds when the ignition is switched on and the distance interval between service appointments has been exceeded or the service interval display was not reset during a service appointment 6 6 13 4 CONTROLS Function buttons 401685 12 You can change the display mode with the MODE button O Possible display modes are total distance traveled TRIP 1 distance 1 ODO and distance 2 TRIP 2 Pressing and holding the SET button e resets the distance 1 TRIP 1 and distance 2 TRIP 2 functions to 0 0 and briefly pressing the SET button e changes the info display to the next display mode Option Without ABS Button e has no function Option With ABS The ABS can be switched off using button 33 6 CONTROLS 6 13 5 Indicator lamps 401686 01 Possible states 34 The turn signal indicator light flashes green simultaneously with the turn signal The turn signal is switched on The engine diagnosis warning lamp MIL lights up red The OBD on board diagnosis has detected an emission or safety critical error The shift warning lights up flashes red The set shift speed has been reached The idling speed indicator lamp lights up green The transmission is shifted to idle The high beam indicator lamp lights up blue The high beam is switched on The immobilizer indicator lamp lights up or flashes red
44. 97 01 11 4 Taking the motorcycle off of the front wheel stand Raise the front of the motorcycle Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Main work Remove the front wheel stand B01388 01 Secure the motorcycle against falling over 11 SERVICE WORK ON THE CHASSIS 11 5 Removing the passenger seat B00712 01 Mount protection cap O Finishing work Take the motorcycle off of the rear wheel stand p 77 Insert the ignition key in seat lock 1 and turn it clockwise Raise the rear of the seat push it towards the rear and remove it upwards Remove the ignition key from the seat lock 80 11 SERVICE WORK ON THE CHASSIS 11 6 Mounting the passenger seat 81 Attach hooks 1 on the passenger seat to brackets 2 on the subframe and lower it at the rear while pushing forward Press down the passenger seat until it clicks into place Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly After mounting the passenger seat check that it is locked correctly by pulling up B00724 10 Finally check that the passenger seat is correctly mounted 11 7 Removing the seat Preparatory work Remove the passenger seat p 80 Main work Remove screws O Raise t
45. Ignition was not switched off when vehicle was parked Action Recharge the battery 4 p 123 Battery is not being charged by alter nator Check the charging voltage amp Check the open circuit current 4 Combination instrument shows nothing on the display Fuse 2 blown Option Without ABS Change the fuses of individual power consumers 7 p 127 Set the clock 7 p 47 Fuse 8 blown Option With ABS Change the fuses of individual power consumers p 127 Set the clock p 47 Speedometer in combination instru ment not functioning Speedometer wiring harness is dam aged or plug in connection is oxidized Check the wiring harness and plug in connection 21 TECHNICAL DATA 21 1 Engine 21 1 1 125 Duke 166 Design 1 cylinder 4 stroke engine water cooled Displacement 125 cm 7 63 cu in Stroke 47 2 mm 1 858 in Bore 58 mm 2 28 in Compression ratio 12 8 1 Control DOHC 4 valves controlled via cam lever chain drive Valve diameter intake 22 5 mm 0 886 in Valve diameter exhaust 19 mm 0 75 in Valve clearance intake cold 0 08 0 12 mm 0 0031 0 0047 in Valve clearance exhaust cold 0 13 0 17 mm 0 0051 0 0067 in Crankshaft bearing Two ball bearings Conrod bearing Sleeve bearing Pistons Cast light alloy Piston
46. M10x1 25 47 Nm 34 7 Ibf ft bearer Screw side stand bracket M10x1 25 29 Nm 21 4 Ibf ft Loctite 243 Screw top shock absorber M10x1 25 50 Nm 36 9 Ibf ft Loctite 243 Stud rear sprocket M10x1 25 50 Nm 36 9 Ibf ft Nut rear wheel spindle M14x1 5 90 Nm 66 4 Ibf ft B Nut swingarm pivot M14x1 5 100 Nm 73 8 Ibf ft Screw top steering head M16x1 5 52 Nm 38 4 Ibf ft Loctite 243 Lambda sensor M18x1 5 20 Nm 14 8 Ibf ft Swingarm bearing adjusting ring M22x1 Tighten and ensure that there is no play 21 TECHNICAL DATA 180 Nut steering head M30x1 Step 1 55 Nm 40 6 Ibf ft 2nd stage loosen counter clockwise 2 turns Step 3 5 Nm 3 7 Ibf ft 22 SUBSTANCES 181 Standard classification DOT Guideline Use only brake fluid that complies with the specified standard see specifications on the container and that exhibits the corresponding properties Recommended supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Guideline Only use high quality coolant with corrosion inhibitor for aluminum motors even in countries with high temperatures Using inferior antifreeze can result in corrosion and foaming Mixture ratio Antifreeze protection 725 45 C 13 anti corrosion antifreeze 49 F distilled water Recommended supplier Motorex COOLANT M3 0 Standard classi
47. Main work Remove expanding rivets O 14 ELECTRICAL SYSTEM Remove screws O Lift the headlight mask slightly and swing forward Remove protection cap O Unplug connector O Detach retaining clamp O Remove headlight bulb O Position the new headlight bulb in the headlight housing Guideline 132 Insert the headlight bulb so that the catches latch into the recesses Headlight H4 socket P43t p 174 Attach retaining clamp O 14 ELECTRICAL SYSTEM ES E z lt gt 2 i Plug in connector Mount protection cap O Fold the headlight mask up Mount and tighten screws e Guideline 133 Screw headlight mask M6 11 Nm 8 1 Ibf ft Loctite 243 Mount expanding rivets 1 on both sides Check that the lighting is functioning properly 14 ELECTRICAL SYSTEM 134 14 7 Changing the parking light bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off all power consumers and switch off the engine Main work Remove expanding rivets O 601915 10 Remove screws O Lift the headlight mask slightly and swing forward 307324 10 14 ELECTRICAL SYSTEM IL E EN B00763 10 Remove scr
48. Reproduction even in part as well as copying of all kinds is permitted only with the express written permission of the copyright owner DEAR KTM CUSTOMER ISO 9001 12 100 6061 24 According to the international quality management standard ISO 9001 KTM uses quality assurance processes that lead to the maximum possible quality of the products Issued by T V Management Service REG NO 12 100 6061 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria TABLE OF CONTENTS 1 MEANS OF REPRESENTATION MM 7 1 1 Symbols U SEQ aiii b EN raise 7 1 2 Formal Us ideis ion is li ibas 8 SAFETY ADVIGCE eite o atada 9 2 1 Use defintlone s dede 9 2 2 Safety adVICe Maa 9 2 3 Degrees of risk and symbols EEEUUUUU 10 2 4 Tampering warning kk 10 2 5 Safe operation A hA A K lsll ll kek 11 2 6 Protective clothing sya tette 12 2 7 Work ft xin iia da 12 2 8 Environment aia rte ee DD neem aces 12 2 9 Owner s Manual M K ke 13 IMPORTANT NOTES 5 icit 0 222 aia 14 3 1 Guarantee warranty i e 14 3 2 Operating and auxiliary substances 14 3 3 Spare parts accessories L L ez 14 3 4 Service zd e oris sisya Pee aee a e Gea villi 14 3 5 FiBllleS 4 dite o eee 15 3 6 Customer sei n i 1y kila te lay iria 15 VIEW OF VEHIGLEE cia altas 16 4 1 View of vehicle front left example 16 4 2 View of vehicle rear right example 18
49. SERIAL NUMBERS oiii cita ias 20 5 1 Chassis n m Der Lo ladies lese toe ep eere har ck G eee k kerb Y 20 5 2 Type label 2 adeo a rt rede re pete e Ce e d eit 20 5 3 Engine UT Der nedin tral it sand ke 21 5 4 Key n tmTiber coc sas ka ee yin a ee o nan P Du n a WE ER n WAA d 21 3 CONTROLS aida 22 6 1 CIUTCH lever AL isi Kak an xuld kulek WANE rete ee ns 22 6 2 Hand brake lever Eu kek 22 6 3 Throttle OF SN e araa e Ml DD 23 6 4 Horn DUttON cc Ld trei keban ads 23 6 5 l3ght SWITCH e corte Ae Pel i 24 6 6 High beam flasher button ooccccoccccconnccncnnnoncnnno 24 6 7 Turn Sig l SWItC Si sil ida 25 6 8 Emergency OFF Witness ett Ee d 25 6 9 Electric starter DUt O J 26 6 10 Ignition steering lOCK E 26 6 11 Locking the steering L E 27 6 12 Unlocking the steering E E 27 6 13 Combination instrument kh 28 6 13 1 OVerVie Wee pae a d n la Perd ned oot 28 6 13 2 Activation and test 29 6 13 3 Warning notes occccccnccoccnccncnnconcnonnnnnconenenonons 30 6 13 4 Function buttons eden acia 33 613 5 Indicator lamps ttbi et ts 34 63 6 Display zerina Ib endete 35 6 13 7 Filling level display in fuel tank 36 613 8 TRIP F display ki 3z aaa namek h w ne ied 37 6 13 9 Coolant temperature indicator 38 6 13 10 Info displasia Gans 39 6 13 11 Riding time average speed menu 40 6 13 12 Aver
50. STEM 145 Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed con tact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Condition The engine is cold Stand the motorcycle upright on a horizontal surface Check the coolant level in the compensating tank O The coolant level must be between MIN and MAX If the coolant level does not match the specified value Correct the coolant level Coolant p 181 B00766 10 Remove the radiator cap e and check the coolant level in the radiator The radiator must be completely filled If the coolant level does not match the specified value Correct the coolant level and find out the cause of the loss Coolant p 181 f you had to add more coolant than the specified amount 0 201 0 21 qt Fill bleed the cooling system 4 p 147 15 COOLING SYSTEM 146 Mount the radiator cap 15 4 Draining the coolant 4 Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator c
51. Screw starter motor M6 12 Nm 8 9 Ibf ft Screw timing chain tensioner M6 12 Nm 8 9 Ibf ft Screw timing chain tensioning rail M6 12 Nm 8 9 Ibf ft Loctite 2437 Screw valve cover M6 12 Nm 8 9 Ibf ft Screw water pump cover M6 12 Nm 8 9 Ibf ft Nut conrod bearing 125 Duke M7 24 Nm 17 7 Ibf ft Screw conrod bearing 200 Duke M7 24 Nm 17 7 Ibf ft Cylinder head manifold nut screw 125 M8 20 Nm 14 8 Ibf ft Duke Cylinder head manifold nut screw 200 M8 20 Nm 14 8 Ibf ft Duke Nut exhaust flange M8 22 Nm 16 2 Ibf ft Screw balancer shaft gear M8 20 Nm 14 8 Ibf ft Loctite 2437 Screw camshaft drive sprocket 125 M8 25 Nm 18 4 Ibf ft Loctite 2437 Duke 21 TECHNICAL DATA 171 Screw camshaft drive sprocket 200 M8 25 Nm 18 4 Ibf ft Loctite 2437 Duke Screw return spring quick shifter M8 12 Nm 8 9 Ibf ft Loctite 2437 Stud exhaust flange M8 22 Nm 16 2 Ibf ft Cylinder head screw 125 Duke M10 Step 1 Thread is oiled head flat is 25 Nm 18 4 Ibf ft greased Step 2 50 Nm 36 9 Ibf ft Oil pressure sensor M10 14 Nm 10 3 Ibf ft Rotor screw M10 46 Nm 33 9 Ibf ft Loctite 243 Screw cylinder head 200 Duke M10 Step 1 Thread is oiled head flat is 25 Nm 18 4 Ibf ft greased Step 2 50 Nm 36 9 Ibf ft Water temperature sensor M10 14 Nm 10 3 Ibf ft Spark plug M12 15 Nm 11 1 Ibf ft N
52. TM workshop 90000 4 O da 401950 11 When conditions allow incline road situation etc you can shift into a higher gear Release the throttle while simultaneously pulling the clutch lever shift into the next gear release the clutch and open the throttle Info You can see the positions of the 6 forward gears in the figure The neutral or idle position is between the first and second gears First gear is used for starting off or for steep inclines The operating temperature is reached when 4 bars of the temperature indicator light up 8 8 5 RIDING INSTRUCTIONS 66 Accelerate only up to a speed suitable for the road surface and weather conditions Par ticularly in bends do not shift and accelerate very carefully To shift down brake if necessary and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Switch off the engine if you expect to be standing for a long time If the engine diagnosis warning lamp lights up during a trip stop immediately switch off the engine and contact an authorized KTM workshop Applying the brakes Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a dirty or wet brake system by riding and braking gently Warning Danger of accidents Reduced braking efficiency caused by spon
53. The ignition is on e The motorcycle is moving Press the SET button briefly and repeatedly until the desired info display appears In this menu the average speed and the average fuel consumption 1 are displayed in L 100 km or L 100 miles 6 CONTROLS 41 Info The average fuel consumption 1 is displayed after several 100 meters of travel after the ignition is switched on If the ignition was switched off for over 60 minutes the display of the average speed and average fuel consumption 1 is reset to O Press the SET button Next display mode on the info display briefly 6 13 13 Average fuel consumption 1 average fuel consumption 2 menu ETEA Y Condition Alternative 1 e The ignition is on e The motorcycle is stationary Alternative 2 e The ignition is on e The motorcycle is moving Press the SET button briefly and repeatedly until the desired info display appears E 10145601 In this menu the average fuel consumption 1 in L 100 km or L 100 miles and the aver age fuel consumption 2 in km L or miles L are displayed e Info The average fuel consumptions 1 and 2 are displayed after several 100 meters of travel after the ignition is switched on If the ignition was switched off for over 60 minutes the display of the average fuel consumption 1 and 2 is reset to O Press the SET button Next display mode on the info display briefly 6 CONTROLS 42 6
54. age speed average fuel consumption 1 MONU A aa cn Era EE Kula a ee DN 40 6 13 13 Average fuel consumption 1 average fuel consumption 2 menu occcoccncnncnnnnccnnnonnnnnncnnnnns 41 TABLE OF CONTENTS 6 13 14 Average fuel consumption 2 service menu 42 6 13 15 Service range MeNU occcoccccnccnncconnncnannnnnnninonons 43 6 13 16 Range riding time menu U 44 6 13 17 Total distance menu ODO sssss 45 6 13 18 Distance menu 1 TRIP 1 sssessesssss 45 6 13 19 Distance menu 2 TRIP 2 ssssssssess 46 6 13 20 Setting kilometers or miles 46 6 13 21 Setting the time ecco eret 47 6 13 22 Adjusting the shift speed RPM 1 48 6 13 23 Adjusting the shift speed RPM 2 48 6 14 Opening the filler Cap occccoccncconnncconnnconnnnnnnns 49 6 15 Closing the filler cap uz 51 6 16 Seatlock ayi xud yanar lan n Minasanikd sen danan Wak 51 6 7 TOO Sei 52 6 18 Grab handleS M khAk h llll kk 52 6 19 Passenger footrests LA h jlhk hK Jsl E 53 6 20 Shift levet carioca ii Hi ned Pac dicas 53 6 21 Foot brake lever MhkA lhE E kk 54 6 22 Si de Stand ikudy yanl e nenale kulane balan eene addon an din 55 7 PREPARING FOR US Escuadra er bA 56 7 1 Advice on first use oooooccccconococnnncnnncnnnnonnnncnnnnnnnoss 56 7 2 Running in the engine A EE 57 7 3 Loading the vehic
55. ap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed con tact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Condition The motor is cold Preparatory work Remove the front spoiler p 93 Main work Position the motorcycle upright Place a suitable container under the engine Remove screw O Remove the radiator cap Completely drain the coolant Mount and tighten screw 1 with a new seal ring B00768 10 15 COOLING SYSTEM 147 Guideline Plug water pump drain hole 125 Duke M6 Plug water pump drain hole 200 Duke M6 Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed con tact a physician immediat
56. cap and insert the ignition key in the lock Note Danger of damage Ignition key breakage To take pressure off of the ignition key push down on the filler cap Damaged igni tion keys must be replaced Turn the ignition key 90 clockwise P Open the filler cap Remove the ignition key 6 CONTROLS 51 Warning Fire hazard Fuel is highly flammable poisonous and harmful to your health After closing the filler cap ensure that it is locked properly Change cloth ing that has been contaminated with fuel Immediately clean contaminated areas on the skin with soap and water Close the filler cap gt Push down the filler cap until the lock engages E P00711 01 The seat lock o is located to the left of the seat It can be locked with the ignition key B00712 01 6 CONTROLS 52 B00758 10 The tool set o is located under the passenger seat B00717 10 The grab handles 1 are used for moving the motorcycle around If you carry a passenger the passenger can hold onto the grab handles during the trip 6 CONTROLS 53 The passenger footrests can be folded in and out Possible states e Passenger footrests folded up For operation without a passenger e Passenger footrests folded down For operation with a passenger Shift lever o is mounted on the left side of the engine 401950 10
57. dding engine Oil ooccccoccnccccccccnnnconcninennnonons 155 CLEANING CARE notre uda sa peo ere Rede ee ER epa 157 18 1 Cleaning the motorcycle essseese 157 18 2 Checks and maintenance steps for winter OPELAllON Pc 159 STORAGE eerte da 161 I9 E STOLA HO iu ati eoa cran dus kana d n Eaa 161 19 2 Preparing for use after storage 162 TROUBLESHOOTING 4 k e 163 TABLE OF CONTENTS 21 TECHNICAL DATA 2l Engine een 21 1 1 125 Duke 21 1 2 200 Duke 21 2 Engine tightening torques 21 3 Capacities 21 3 1 Engine oil 21 3 2 Coolant 2173 3 RUE iiie sees 21 4 Chassis sssssss 21 5 Electrical system 21 6 IIS ic ERR 21 7 A r ma d nae bak Kek 21 8 Shock absorber 21 9 Chassis tightening torques SUBSTANCES kk 1 1 1 MEANS OF REPRESENTATION Symbols used The meaning of specific symbols is described below f gt x 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 There your motorcycle will be optimally
58. discs are destroyed Check the brake linings regularly 12 BRAKE SYSTEM 100 Check the brake linings for minimum thickness O Minimum thickness gt 1 mm gt 0 04 in Ifthe minimum thickness is less than specified Change the front brake linings Check the brake linings for damage and cracking If there is wear or tearing Change the front brake linings 4 Warning Jb Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to over heating Adjust the free travel on foot brake lever according to specifications 12 BRAKE SYSTEM 101 Disconnect spring O Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel O Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the free travel of the foot brake lever amp p 101 Reconnect spring O o GG ra 12 7 Adjusting the free travel of the foot brake lever A Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to over heating Adjust the free travel on foot brake lever according to
59. e adj ti SL ng 3 2d erts De os DIE te za E E 47 Tire air pressure CNECKINE a eR s a dee RA 119 INDEX Tire condition checkings wos c mde tus qut ct e eatin foh 118 Toolset 22 25 83 kk Kl a bd CER AUR FUR ROS 52 Transport ayn E Kira Za lh aka Qi e E a Ap Ki esu RS 70 Troubleshooting 0 000 ee aes 163 165 Turn signal switch o oo o o cece ee eee 25 Type label dat ak a wad a awek is wla do 20 Use definition 24i ub eel EE e desti pe ams 9 View of vehicle Trontletb Stitt Antes sts ds a e besos die a a 16 CAMEO is OU CRAS ao 18 Warranty aaa a Ea Gent ea 14 Winter operation checks and maintenance steps o o oo oo oo 159 WorkiruleS i1 ic RR ree ee eR eed HN NE 12 191 WWW KTM COM 3213278en 01 2015 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM
60. e ABS warning lamp starts flashing ABS is deactivated 401685 15 Pull the clutch lever engage 1st gear release the clutch lever slowly and simultaneously open the throttle carefully e Tip If the engine dies while starting off only pull the clutch lever and press the electric starter button You do not need to shift into neutral Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control Avoid abrupt load alterations and sudden braking actions and adapt your speed to the road conditions A Warning AX Danger of accidents If you change down at high engine speed the rear wheel can lock up Do not change into a low gear at high engine speed The engine races and the rear wheel can lock up ep gt gt RIDING INSTRUCTIONS 64 Warning Danger of accidents Malfunctions caused by incorrect ignition key position Do not change the ignition key position during a journey Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle Make all adjustments when the vehicle is at a standstill Warning Risk of injury Falling off of the passenger The passenger must be seated properly on the passenger seat and hold on to the front rider or the grab handles The feet must be positioned on the passenger footrests Note the regulations governing the minimum age of passengers Warning Danger of accidents Danger of accid
61. e environment Do not allow fuel to get into the ground water the ground or the sewage system Use operating and auxiliary substances such as fuel and lubricants as specified in the Owner s Manual 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 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 Incorrect adjustment and tuning of the engine and chassis can lead to damage and breakage of components 3 IMPORTANT NOTES 15 Use of the vehicle under difficult conditions such in rain high heat or with a heavy load can lead to considerably more rapid 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
62. e in well ventilated rooms Inthe event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician 14 ELECTRICAL SYSTEM 124 Warning Environmental hazard The battery contains elements that are harmful to the environment Do not dispose of batteries with the household waste Dispose of a defective battery in an environmentally friendly manner Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries Info Even when there is no load on the battery it discharges steadily The charging level and the method of charging are very important for the service life of the battery Rapid recharging with a high charging current shortens the battery s service life If the charging current charging voltage or charging time is exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and sulfate destroying the battery The battery is maintenance free The acid level does not have to be checked Preparatory work Switch off all power consumers and switch off the engine Remove the passenger seat p 80 Remove the seat p 81 Disconnec
63. e motorcycle with the front wheel stand p 78 Main work Option Without ABS Loosen screw O by several rotations Release screws O Press on screw 1 to push the wheel spindle out of the axle clamp Remove screw O Warning Danger of accidents Reduced braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not damaged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork e Info Do not pull the hand brake lever when the front wheel is removed 13 WHEELS TIRES 108 Option With ABS Remove screws o and push the fender to the side Remove screw e and pull wheel speed sensor e out of the hole Loosen screw o by several rotations Release screws O Press on screw o to push the wheel spindle out of the axle clamp Remove screw O Warning Danger of accidents Reduced braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not damaged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork e Info Do not pull the hand brake lever when the front wheel is removed Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when n
64. ecessary 13 WHEELS TIRES 109 Main work Option Without ABS Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the wheel bearing 4 Clean and grease the shaft seal rings 1 and mating surfaces O of the spacers Long life grease p 184 Insert the spacers Clean the thread of the wheel spindle and screw O Position the front wheel and insert the wheel spindle Y The brake linings are correctly positioned Mount and tighten screw O Guideline Screw front wheel spindle M8 26 Nm 27 19 2 Ibf ft Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point B00744 10 Take the motorcycle off of the front wheel stand p 79 Operate the front brake and compress the fork a few times firmly Y The fork legs straighten Tighten screws O Guideline Screw fork stub M8 15 Nm 11 1 Ibf ft 13 WHEELS TIRES 1801391 11 Option With ABS 110 Check the wheel bearing for damage and wear Ifthe wheel bearing is damaged or worn Change the wheel bearing 4 Clean and grease the shaft seal rings 1 and mating surfaces O of the spacers Long life grease p 184 Insert the spacers Clean the thread of the wheel spindle and screw e Positio
65. ee WA Qe x 150 Combination instrument activation and test lk Sesh tea a ale 29 average fuel consumption l average fuel consumption 2 TIVO TUN N os dee sides tintin Ge QURE Su A bc oh eee t Deo Ain cede 41 average fuel consumption 2 service menu 42 average speed average fuel consumption 1 menu 40 coolant temperature indicator o o o oooooo 38 DISPLAY ias A RE DAE tate 35 INDEX display TRIP 3 connected aaa eee was 37 distance menu 1 TRIP1 45 distance menu 2 TRIP2 46 filling level display in fuel tank o o o oo o oo 36 FUNCTION buttons ci be lill4 e ala 33 indicator lamps ascia dud a he a 34 Info display ios ey yea abere rie p RT 39 range riding time menu llle 44 riding time average speed menu llle 40 service range menu a 43 total distance menu ODO o o ooooo 45 WarnIng riot6S ofret aeoaea ia up ERU ae aged 30 Coolant Gramineae denas end RR predi ar ege e 146 Coolant level Checking ok eros reed TE a Ku AD seda 142 144 Cooling system lll llle 141 filling bleeding 3 si mete SE SOS 147 Customer service kk kk kK KK RIK KI KIRI KI K KIR KI essen 15 E Electric starter button A KK KK KIRR ooo 26 Emergency OFF switch o o o oooo oo 25 Engine TUN DIN TS Ay cc Dn dank KU ohn Ue AN N eg oe at cela eRe 57 Engine number gt 3
66. elmet boots gloves pants and jacket with protectors every time you ride the vehicle Always wear protective clothing that is in good condition and meets the legal requirements In the interest of your own safety KTM recommends that you only operate the vehicle while wearing protective clothing Special tools are necessary for certain tasks The tools are not contained in the vehicle but can be ordered under the number in parenthe ses E g bearing puller 15112017000 During assembly non reusable parts e g self locking screws and nuts seals and seal rings O rings pins lock washers must be replaced by new parts In some instances a thread locker e g Loctite is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them for damage and wear Change damaged or worn parts After you complete the repair or service work check the operating safety of the vehicle 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 veh
67. ely Change clothing that is contaminated with coolant Keep coolant out of reach of children 8 Nm 5 9 Ibf ft 8 Nm 5 9 Ibf ft Main work Remove radiator cap O AER 15 COOLING SYSTEM 148 Release bleeder screw O by three turns Tilt the vehicle slightly to the right Pour in coolant until it emerges without bubbles at the bleeder screw and then mount and tighten the bleeder screw immediately Coolant p 181 Fill the radiator completely with coolant Mount the radiator cap Rest the vehicle on the side stand Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and let it run warm Stop the engine and allow it to cool down When the engine is cool check the coolant level in the radiator and if necessary add coolant Remove the cap of the compensating tank e and top up the coolant level up to the MAXmarking Mount the cap of the compensating tank Finishing work Fit the front spoiler p 94 16 TUNING THE ENGINE 149 400192 11 Check the throttle grip for smooth operation Move the handlebar to the straight ahead position Move the throttle grip back and
68. ents caused by dangerous driving Comply with traffic regulations and ride defensively and foresightedly to detect sources of danger early on Warning Danger of accidents Reduced road grip with cold tires On every journey take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured Warning Danger of accidents Reduced road grip with new tires New tires have a smooth rolling surface and therefore cannot provide full road grip The entire rolling surface must be rough ened in the first 200 kilometers 124 3 miles by moderate riding at alternating angles The full grip levels are not achieved until the tires have been run in 8 RIDING INSTRUCTIONS Warning 65 Danger of accidents Unstable handling characteristics due to slipped baggage Check the way your baggage is fixed regularly Warning Danger of accidents Lack of roadworthiness After a fall check the vehicle as usual before preparing for use Note Engine failure Overheating of engine Ifthe coolant temperature warning lamp lights up stop and switch off the engine Allow the engine to cool down and check the coolant level in the radiator and top up if necessary If you continue with the coolant temperature warning lamp alight you may have engine failure e Info If you hear unusual noises while riding stop immediately switch off the engine and contact an authorized K
69. erminal cover Disconnect negative cable e from the battery 14 ELECTRICAL SYSTEM 122 Pull back the positive terminal cover e Disconnect positive cable from the battery Detach rubber band O Pull the battery up and out of the battery holder e info Never operate the motorcycle with a discharged battery or without a battery In both cases electrical components and safety devices can be damaged The vehi cle is therefore no longer roadworthy Main work Position the battery in the battery holder Guideline The battery terminals must be facing upward Alternative 1 125 Duke Battery FTZ 7 p 173 Alternative 1 200 Duke Battery FTZ 9 7 p 174 Attach rubber band Position the positive cable O and mount and tighten the screw Position positive terminal cover 14 ELECTRICAL SYSTEM 123 Position the negative cable o and mount and tighten the screw Position the negative terminal cover Finishing work Mount the seat p 82 Mount the passenger seat p 81 Set the clock p 47 KT Warning y Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep sparks and open flames away from the battery Only charg
70. ews O Remove cover O Pull the socket with bulb e out of the housing Remove the bulb Position a new light bulb in the socket 135 Parking light W5W socket W2 1x9 5d p 174 Position the socket with bulb O in the housing 14 ELECTRICAL SYSTEM gt gO B A P3 bf s Position cover O Mount and tighten screws O Fold the headlight mask up Mount and tighten screws O Guideline Screw headlight mask M6 11 Nm Loctite 243 8 1 Ibf ft Mount expanding rivets on both sides Check that the lighting is functioning properly 14 ELECTRICAL SYSTEM 137 14 8 Checking the headlight setting Position the vehicle upright on a horizontal surface in front of a light wall and make a O mark at the height of the center of the low beam headlight E gt Make another mark at a distance B under the first mark eee id Guideline o A Distance 5 cm 2 in Position the vehicle perpendicular to the wall at a distance A from the wall and switch on the low beam Guideline 400726 10 Distance 5 m 16 ft The rider with luggage and passenger if applicable now mounts the motorcycle Check the headlight setting The light dark boundary must lie exactly on the lower mark when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applicable
71. ex Fuel Stabilizer Recommended supplier Motorex Bike Grease 2000 Recommended supplier Motorex Moto Clean 23 AUXILIARY SUBSTANCES 185 Recommended supplier Motorex Moto Polish amp Shine Recommended supplier Motorex Moto Protect Recommended supplier Motorex Quick Cleaner Recommended supplier Motorex Joker 440 Synthetic 24 STANDARDS 186 JASO A IL Different technical development directions required a new specification for 4 stroke motorcycles the JASO T903 MA Standard Ear lier engine oils from the automobile industry were used for 4 stroke motorcycles because there was no separate motorcycle specification Whereas long service intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Stan dard meets these special requirements The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscos ity The viscosity describes only one property of oil and says nothing about quality A ABS a Ratte d ok var a ae Seale de mt 95 ACCeSSOLIBS ccoo s See e on RU pe UV UE RU da 14 Antifreeze CHECKING uec esee some var es e OR eg ORIS gium 142 Antilock brake system o o ooooooooo 95 Auxiliary substances llle 14 B
72. exactly you will ensure a much longer service life for your motorcycle 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 disassem ble the component to perform the activity in question Please follow the instructions in the text 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 4 4 1 VIEW OF VEHICLE View of vehicle front left example S00654 10 4 VIEW OF VEHICLE 17 Combination instrument Rear mirror Clutch lever p 22 Seat Passenger seat Seat lock p 51 Grab handles p 52 Engine number p 21 O 00 NI AI O1 O N Side stand p 55 mm o Shift lever p 53 4 4 2 VIEW OF VEHICLE View of vehicle rear right example S00655 10 4 VIEW OF VEHICLE 19 Tool set p 52 Light switch p 24 High beam flasher button p 24 Turn signal switch p 25 Horn button p 23 Filler cap Electric starter button p 26 Emergency OFF switch p 25 Hand brake lever p 22 Ignition steering lock p 26
73. fication JASO T903 MA p 186 SAE p 186 SAE 15W 50 22 SUBSTANCES 182 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Partially synthetic engine oil Recommended supplier Motorex Formula 4T Standard classification JASO T903 MA p 186 SAE p 186 SAE 10W 40 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Partially synthetic engine oil Recommended supplier Motorex Formula 4T Standard classification SAE p 186 SAE 4 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding proper ties 22 SUBSTANCES 183 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use e Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 23 AUXILIARY SUBSTANCES 18 Ex Recommended supplier Motorex Chain Clean Guideline Recommended supplier Motorex Chainlube Road Recommended supplier Motor
74. g surfaces O of the spacers Long life grease p 184 Clean threads of wheel spindle and axle nut Clean the fixing locations on the brake caliper support and swingarm Install the rubber damper and rear sprocket carrier on the rear wheel Position the rear wheel Y The brake linings are correctly positioned Position the rear wheel on the contact surfaces in the swingarm Push the rear wheel as far forward as possible and place the chain on the rear sprocket 13 WHEELS TIRES 115 Pull the rear wheel back and mount wheel spindle e with the washer and chain adjuster O Guideline Mount the left and right chain adjusters o in the same position Mount nut e and washer Push the rear wheel forward so that the chain adjusters are on the screws and tighten nut Guideline In order for the rear wheel to be correctly aligned the markings on the left and right chain adjusters must be in the same position relative to the reference marks O Nut rear wheel spindle M14x1 5 90 Nm 66 4 Ibf ft Option With ABS Check the rear hub rubber dampers 4 p 117 Check the wheel bearing for damage and wear Ifthe wheel bearing is damaged or worn Change the wheel bearing 4 Clean and grease the shaft seal rings 1 and mating surfaces O of the spacers ul e 9 EAS 3 Ya Sp Long life grease p 184 9
75. gy pressure point of front or rear brake Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Failure of brake system Ifthe foot brake lever is not released the brake linings drag continuously The rear brake may fail due to overheating Take your foot off the foot brake lever when you are not braking Warning Danger of accidents Longer stopping distance due to higher overall weight Take the longer stopping distance into account when carrying a passenger and baggage 8 RIDING INSTRUCTIONS 67 Warning Danger of accidents Delayed brake action on salted roads There may be salt deposits on the brake discs In order to restore the normal braking efficiency you will need to remove the deposits from the discs by carefully applying the brakes Option Without ABS Warning Danger of accidents f you brake too hard the wheels can lock Adapt your braking to the traffic situation and the road conditions When braking release the throttle and apply the front and rear brakes at the same time On sandy wet or slippery surfaces use the rear brake Braking should always be completed before you go into a bend Change down to a lower gear appropriate to your road speed On long downhill stretches use the braking effect of the engine Change down one or two gears but do not over rev the engine In this way you have to brake far less and
76. he rear of the seat pull it towards the rear and remove it upwards 11 SERVICE WORK ON THE CHASSIS 82 11 8 Mounting the seat Main work Attach seat recesses O at screws 1 and lower at the rear Mount and tighten screws e Guideline Screw seat M6 10 Nm 7 4 Ibf ft B00727 10 Finishing work Mount the passenger seat p 81 11 SERVICE WORK ON THE CHASSIS 11 9 Checking for chain dirt accumulation Check the chain for coarse dirt accumulation lt gt Ifthe chain is very dirty Clean the chain p 83 400678 01 11 10 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations 83 11 SERVICE WORK ON THE CHASSIS 84 e Info The service life of the chain depends largely on its maintenance Preparatory work Raise the motorcycle with the rear wheel stand p 77 Ll Main work Clean the chain regularly Rinse off
77. hicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Note Material damage Premature clogging of the fuel filter n some countries and regions the available fuel quality and cleanliness may not be sufficient This will result in problems with the fuel system Your authorized KTM workshop will be glad to help Only refuel with clean fuel that meets the specified standards Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system 8 RIDING INSTRUCTIONS B00719 10 Switch off the engine Open the filler cap p 49 Fill the fuel tank with fuel up to the lower edge o of the fuel filler 72 Total fuel tank capacity approx 11 2 9 US gal Super unleaded ROZ 95 RON 95 PON 91 p 183 Close the filler cap p 51 9 SERVICE
78. icles there are no legal regulations that per tain to the disposal of an end of life motorcycle Your authorized KTM dealer will be glad to advise you 2 SAFETY ADVICE 13 29 Owner s Manual 00 It is important that you read this Owner s Manual carefully and completely before making your first trip The Owner s Manual contains use ful information and many tips on how to operate handle and maintain 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 should be handed over to the new owner if the vehicle is sold 3 IMPORTANT NOTES 1 A The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer s Service amp Warranty Booklet and in the KTM Dealer net otherwise all warranty claims will be void No warranty claims can be considered for damage resulting from manipulations and or alterations to the vehicle Additional information on the guarantee or warranty and the procedures involved can be found in the Service amp Warranty Booklet Warning Environmental hazard Improper handling of fuel is a danger to th
79. ing Press the MODE button briefly and repeatedly until TRIP 1 appears on the display TRIP 1 shows the distance covered since the last reset For example the distance from one refueling stop to the next TRIP 1 is always running and counts up to 999 9 6 CONTROLS 6 13 19 Distance menu 2 TRIP 2 6 13 20 Setting kilometers or miles e Info Make the country specific setting 46 Press the SET button Display of TRIP 1 is reset for 5 10 seconds Press the MODE but Next display mode on the display ton Condition Alternative 1 e The ignition is on e The motorcycle is stationary Alternative 2 e The ignition is on e The motorcycle is moving Press the MODE button briefly and repeatedly until TRIP 2 appears on the display TRIP 2 shows the distance covered since the last reset For example the distance from one refueling stop to the next TRIP 2 is always running and counts up to 999 9 Press the SET button Display of TRIP 2 is reset for 5 10 seconds Press the MODE but Next display mode on the display ton Condition The ignition is on 6 CONTROLS 41 The motorcycle is stationary Press the MODE button briefly and repeatedly until ODO appears on the display Press the MODE button for 5 10 seconds X The display changes from km h to mph or from mph to km h 6 13 21 Setting the time Condition The ignition is on The motorc
80. ing Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Warning Danger of accidents Reduced road grip with new tires New tires have a smooth rolling surface and therefore cannot provide full road grip The entire rolling surface must be rough ened in the first 200 kilometers 124 3 miles by moderate riding at alternating angles The full grip levels are not achieved until the tires have been run in Info When using your vehicle remember that others may feel disturbed by excessive noise 7 PREPARING FOR USE 57 Make sure that the pre delivery inspection work has been carried out by an authorized KTM workshop Y You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover Before your first trip read the entire operating instructions carefully Get to know the controls Get used to handling the motorcycle on a suitable piece of land before making a longer trip Try also to ride as slowly as possible to get a better feel for the vehicle Hold the handlebar firmly with both hands and keep
81. interrupted a running engine stops and a non running engine cannot be started Emergency OFF switch on This position is required for operation the igni tion circuit is closed 6 CONTROLS S00662 10 The electric starter button 1 is fitted on the right side of the handlebar Possible states e Electric starter button in basic position e Electric starter button pressed In this position the electric starter is actuated Ex The ignition steering lock is in front of the upper triple clamp Possible states Ignition OFF In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start The ignition key can be removed Ignition ON In this position the ignition circuit is closed and the engine can be started Steering locked In this position the ignition circuit is interrupted and the steering locked The ignition key can be removed 6 CONTROLS 27 Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Park the vehicle Turn the handlebar all the way to the left Insert the key into the ignition handlebar lock press in and turn to the left Remove the key Y Steering is no longer possible 400732 01 Insert the key into the ignition handlebar lock press in and
82. ion KII KII KIRI KI KII KIRI K K KI KIR 11 Seat nen uu zar ma a Sica utr we a 82 REMOVING 2s 20s comu eB aed ih Ss 81 Seatlock oca UU eta ae dcs eae 51 SOMVICO uso Hasta af RRA HHHH HHHH HHHH HH 14 Service schedule 000000 ooo 73 74 Shift leVer i uu an kd uh il Se Dae de dal lekar WE Sea 53 AGUSTIN a De DD xe RN ERU S 76 Shift speed RPM 1 ad stirig cidem E Ie e GE a Gant ating du RUE 48 Shift speed RPM 2 adjustirig esu ER RR e em A aia 48 Shifting cu omoes HH Hz 63 190 Shock absorber spring preload adjusting 0 0 00 eee eee 75 SIDO SHO oca BA A az Aen ae Bk PORTS 55 Spare Pants uoces ke sa a dee REA RES 14 Starting BN DD a e di in cado Da da de a 61 Steering DENSA ict acd ri a Mcd 27 UNIOCKING urne it a kr ee ee Dan or ede 27 Steering lock sess a a ee E EE RH 26 StOppIng s tua door act ee CUERO RUE ette As 68 p l MB a Sones Bae a wl a ee tae te te HH ue 161 T Technical data Capacitan ee HH eed 171 CHASSIS ebrei ein AS Eee OES Gea dn 172 chassis tightening torques 0000 eee eee 175 electrical system gt A Abd d ka ka Pk a Wn xira ee 173 eflglllg iue eR dr alaya RE a a r e d SE ATE 166 engine tightening torques o oooooooooooo o 169 TORK ka dude A A oi qoe d 175 shock absorber cx cu tW REPRE TERMES 175 MOS Lol et aL eae res A tera db rus Beart te ens S IDE ERA 174 Throtte Srlp zzi kn PES Bak aoe fate to vtr E 23 Tim
83. ituation of the spring process on the shock absorber The best spring preload setting is achieved when it is set for the weight of the rider and that of any baggage and a passenger thus ensuring an ideal compromise between maneuverability and stability Turn adjusting ring 1 to adjust the spring preload Guideline Spring preload Standard 3 clicks Full payload 6 clicks Hook wrench T106S BO1419 10 e Info The spring preload can be set to 10 different positions 10 TUNING THE CHASSIS 76 10 2 Adjusting the shift lever e Info The adjustment range of the shift lever is limited S00667 10 Loosen nuts O Adjust the shift lever by turning shift rod O Guideline Shift rod adjustment range 110 122 mm 4 33 4 8 in e Info Make the same adjustments on both sides At least five screw threads must be screwed into the seating Check adjusting angle O Guideline Adjusting angle shift rod deflector 90 shift lever Tighten nuts O e Info After the nuts have been tightened the bearings of the shift rod must be cen trally and identically aligned to each other in order to ensure freedom of move ment in the bearing shells Check the shift lever to ensure it is functioning properly and can move freely 11 SERVICE WORK ON THE CHASSIS 77 11 1 Raising the motorcycle with the rear wheel stand Note Danger of damage
84. king the chain rear sprocket and engine Folios p 89 11 14 Removing the front spoiler sseesesssssse 93 TABLE OF CONTENTS 12 13 14 11 15 Fitting front spoiler E 94 BRAKE SYSTEM 5 55 riii cb seven Ta ye V H k 95 12 1 ABS antilock brake system Option With ABS 95 12 2 Checking the brake diSCS oocccccocccconnccoccnccncnnns 96 12 3 Checking the brake fluid level of the front brake 97 12 4 Adding front brake fluid X 98 12 5 Checking the front brake linings 99 12 6 Checking the free travel of foot brake lever 100 12 7 Adjusting the free travel of the foot brake O A mm g 2 o og0o0 r rT 101 12 8 Checking the rear brake fluid level 102 12 9 Adding rear brake fluid A UUUEEEEEUUUUUUEUL 104 12 10 Checking the rear brake linings 105 WHEELS TIRES u sin seneda kalike aa 107 13 1 Removing the front wheel 4 107 13 2 Installing the front wheel 3 108 13 3 Removing the rear wheel amp UUUE 111 13 4 Installing the rear wheel A amp 113 13 5 Checking the rear hub rubber dampers 4 117 13 6 Checking the tire condition 118 13 7 Checking the tire air pressure 119 ELECTRICAL SYSTEM cons ada 121 14 1 Removing the ba
85. le h h ke 58 8 RIDING INSTRUCTIONS kk k 60 8 1 Checks and maintenance when preparing for Ire 60 8 2 jeans 61 8 3 Starting off 63 8 4 Shifting riding cooocccccccnncononononnnconenonononcnancnnon 63 10 11 4 8 5 Applying the brakes ccooccnccocccccncnonocnncnnoncnnnona 66 8 6 Stopping parkig moasa aani 68 8 7 Transpor a is 70 8 8 Retenes ido 71 SERVICE SCHEDULE M44 kk kk kk kk kk kk k 73 9 1 Service SchedUule M AEE kk kk k 73 TUNING THE CHASSIS 5 li sya iyar cocci n beka krdn k kj 75 10 1 Adjusting the spring preload of the shock absorber V sayiy dawaya tete saa ar s k keka ria de ya w ye EAE 75 10 2 Adjusting the shift lever A E 76 SERVICE WORK ON THE CHASSIS 77 11 1 Raising the motorcycle with the rear wheel cnm 77 11 2 Taking the motorcycle off of the rear wheel cnm 77 11 3 Raising the motorcycle with the front wheel ccn 78 11 4 Taking the motorcycle off of the front wheel stand ic Aa Ae dan 79 11 5 Removing the passenger seat UUUU 80 11 6 Mounting the passenger seat UUU 81 11 7 Removing the seat 11 8 Mounting the seat 11 9 Checking for chain dirt accumulation 83 11 10 Cleaning the chain h h Ei E 83 11 11 Checking the chain tension esses 84 11 12 Adjusting the chain tension 86 11 13 Chec
86. lo Front 2 0 bar 29 psi Rear 2 0 bar 29 psi Tire air pressure with passenger full payload Front 2 0 bar 29 psi Rear 2 2 bar 32 psi Secondary ratio 125 Duke 14 45 Secondary ratio 200 Duke 14 42 Chain 5 8 x 1 4 520 X ring Steering head angle 65 Wheelbase 1 367x15 mm 53 82 0 59 in Seat height unloaded 800 mm 31 5 in Ground clearance unloaded 170 mm 6 69 in Dry weight 125 Duke 127 kg 280 Ib Dry weight 200 Duke 129 5 kg 285 5 Ib 21 5 Electrical system Battery 125 Duke FTZ 7 Battery voltage 12 V Nominal capacity 6 Ah Maintenance free 21 TECHNICAL DATA 174 Battery 200 Duke FTZ 9 Battery voltage 12 V Nominal capacity 8 Ah Maintenance free Fuse 75011088010 10A Fuse 75011088015 15A Fuse 90111088025 25A Fuse 75011088030 30A Headlight H4 socket P43t 12V 60 55 W Parking light W5W socket W2 1x9 5d 12V BW Instrument lights and indicator lamps LED Turn signal LED Brake tail light LED License plate lamp LED 21 6 Tires Front tires Rear tires 110 70 R 17 M C 54S TL 150 60 R 17 M C 66S TL MRF revz FC MRF revz C Additional information is available in the Service section under http www ktm com 21 TECHNICAL DATA 175 21 7 Fork Fork part number 90601000044 Fork WP Suspension Fork length 736 m
87. loose dirt with a soft jet of water Remove old grease remains with chain cleaner lt Chain cleaner p 184 9693836 After drying apply chain spray Chain lube for road use p 184 400725 01 Finishing work Take the motorcycle off of the rear wheel stand p 77 11 11 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain is too taut the components of the secondary power transmission chain engine sprocket rear sprocket bearings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme cases If the chain is too loose however it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine Ensure that the chain tension is correct and adjust it if necessary 11 SERVICE WORK ON THE CHASSIS 85 Lean the motorcycle on the side stand Shift gear to neutral Inthe area of chain sliding guard press the chain upward toward the swingarm and determine chain tension e Info I The upper chain section B must be taut Chain wear is not always even so you should repeat this measurement at differ ent chain positions Chain tension 5 7 mm 0 2 0 28 in Ifthe chain tension does not meet specifications Adjust
88. ly its value and appearance will be maintained over a long period Avoid direct sunshine on the motorcycle during cleaning Seal the exhaust system to keep water out N First remove coarse dirt particles with a gentle spray of water Spray very dirty areas with a normal motorcycle cleaner and then clean with a paint brush Motorcycle cleaner p 184 401061 01 18 CLEANING CARE 158 e Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the vehicle with water first If the vehicle was operated in road salt clean it with cold water Warm water would enhance the corrosive effects of salt After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the closure of the exhaust system Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake sys tem Clean or dry a dirty or wet brake system by riding and braking gently After cleaning ride the vehicle a short distance until the engine warms up e Info The heat produced causes water at inaccessible locations in the engine and on the brake system to evaporate Push back the sleeves of the handlebar controls to allow any water that has penetrated to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 83 Treat bare
89. m 28 98 in Fork oil 450 ml 15 21 fl oz Fork oil SAE 4 4860116651 p 182 21 8 Shock absorber Shock absorber part number 90604010000 Shock absorber WP Suspension Spring preload Standard 3 clicks Full payload 6 clicks Static sag 15 mm 0 59 in Riding sag 45 50 mm 1 77 1 97 in Fitted length 300 mm 11 81 in 21 9 Chassis tightening torques Exhaust clamp 19 Nm 14 Ibf ft Helmet holder screw EJOT PT9 3 Nm 2 2 Ibf ft Screw chain guard EJOT PT9 4 Nm 3 Ibf ft Screw headlight EJOT PT9 4 Nm 3 Ibf ft Remaining screws chassis MA 4 Nm 3 Ibf ft Screw EFI control unit M4 5 Nm 3 7 Ibf ft 21 TECHNICAL DATA 176 Screw trim subframe bottom M4 2 Nm 1 5 Ibf ft Remaining nuts chassis M5 5 Nm 3 7 Ibf ft Remaining screws chassis M5 5 Nm 3 7 Ibf ft Screw ABS hose clamp Option With M5 7 Nm 5 2 Ibf ft ABS Screw brake line holder rear M5 7 Nm 5 2 Ibf ft Loctite 243 Screw chain guard M5 4 Nm 3 Ibf ft Loctite 243 Screw fuel pump M5 5 Nm 3 7 Ibf ft Screw fuel tank closure flange M5 5 Nm 3 7 Ibf ft Screw fuel tank cover M5 4 Nm 3 Ibf ft Screw fuel tank trim M5 5 Nm 3 7 Ibf ft Screw license plate holder M5 11 Nm 8 1 Ibf ft Screw license plate lamp M5 2 Nm 1 5 Ibf ft
90. n fuse Fuse 2 15 A start auxiliary relay alarm system OPTIONAL Fuse 3 15 A control unit power relay Fuse 4 15 A ignition coil Fuse 5 15 A radiator fan Fuse 6 15 A horn brake light turn signal high beam low beam parking light tail light license plate lamp Fuse 7 10 A ABS control unit Fuse 8 10 A combination instrument control unit Fuse 9 10 A auxiliary equipment e Info A defective fuse is indicated by a burned out fuse wire Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never bypass or repair fuses Use spare fuses with the correct rating only Fuse 75011088010 p 174 Fuse 75011088015 p 174 Fuse 75011088030 p 174 14 14 6 ELECTRICAL SYSTEM 131 e Tip Replace the spare fuse in the fuse box so that it is available if needed Check that the power consumer is functioning properly Close the fuse box cover Finishing work Mount the passenger seat p 81 Changing the headlight bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off all power consumers and switch off the engine
91. n the front wheel and insert the wheel spindle Y The brake linings are correctly positioned Mount and tighten screw e Guideline Screw front wheel spindle M8 26 Nm 19 2 Ibf ft Position wheel speed sensor e in the drill hole Mount and tighten screw O Guideline Screw wheel speed sensor holder M6 8 Nm 5 9 Ibf ft Mount and tighten screws O Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Take the motorcycle off of the front wheel stand p 79 Operate the front brake and compress the fork a few times firmly 13 WHEELS TIRES 1n Y The fork legs straighten Tighten screws O Guideline Screw fork stub M8 15 Nm 11 1 Ibf ft Finishing work Take the motorcycle off of the rear wheel stand p 77 Preparatory work Raise the motorcycle with the rear wheel stand p 77 13 WHEELS TIRES 112 Main work Option Without ABS Remove nut and washer Remove chain adjuster Hold rear wheel and wheel spindle pull out with washer and chain adjuster Push the rear wheel forward as far as possible and take the chain off the rear sprocket Warning Danger of accidents Reduced braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not damaged Pull the rear wheel back and take it out of the swingarm
92. nd and move up all the way Turn the emergency OFF switch to the position Switch on the ignition by turning the ignition key to the position w After you switch on the ignition you can hear the fuel pump working for about two seconds The function check of the combination instrument is run at the same time Shift gear to neutral Y The green idling speed indicator lamp N lights up Option With ABS X The ABS warning lamp lights up and goes back out after starting off Press the electric starter button e Info Do not press the electric starter button until the combination instrument func tion check is finished When starting DO NOT open the throttle If you open the throttle during the start ing procedure fuel is not injected by the engine management system and the engine cannot start Press the starter for a maximum of 5 seconds Wait for a least 5 seconds before trying again This motorcycle is equipped with a safety starting system You can only start the engine if the transmission is in neutral or if the clutch is pulled when a gear is engaged If the side stand is folded out and you shift into gear and release the clutch the engine stops 8 RIDING INSTRUCTIONS 63 Switching off ABS Option With ABS KTM recommends riding with ABS at all times However situations may arise in which ABS is not advantageous Condition Vehicle stationary engine running Press the 1 button for 3 5 seconds Y Th
93. ndividual power consumers is located under the passenger seat 14 ELECTRICAL SYSTEM 128 Preparatory work Switch off all power consumers and switch off the engine Remove the passenger seat p 80 Main work Option Without ABS Open fuse box cover O Remove the defective fuse Guideline Fuse 1 30 A main fuse Fuse 2 15 A combination instrument Fuse 3 10 A control unit power relay Fuse 4 15 A ignition coil alarm system OPTIONAL Fuse 5 15 A radiator fan Fuse 6 15 A horn brake light turn signal high beam low beam parking light tail light license plate lamp B00754 10 e Info A defective fuse is indicated by a burned out fuse wire O 14 ELECTRICAL SYSTEM 129 Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never bypass or repair fuses Use spare fuses with the correct rating only Fuse 75011088010 p 174 Fuse 75011088015 p 174 Fuse 75011088030 p 174 e Tip Replace the spare fuse in the fuse box so that it is available if needed Check that the power consumer is functioning properly Close the fuse box cover Option With ABS Open fuse box cover O 14 ELECTRICAL SYSTEM 130 Remove the defective fuse Guideline Fuse 1 30 A mai
94. nger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning A Danger of accidents Uncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Info The type condition and air pressure of the tires all have a major impact on the riding behavior of the motorcycle Worn tires have a negative effect on riding behavior especially on wet surfaces 13 WHEELS TIRES XK 400602 10 13 7 Checking the tire air pressure 119 Check the front and rear tires for cuts run in objects and other damage If the tires exhibit cuts run in objects or other damage Change the tires Check the depth of the tread e Info Note local national regulations concerning the minimum tread depth Minimum tread depth gt 2 mm gt 0 08 in Ifthe tread depth is less than the minimum permissible depth Change the tires Check the age of the tires e Info l The tire s date of the manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture KTM recommends
95. nsures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions 125 C 257 F h B00765 10 15 COOLING SYSTEM 142 The coolant is cooled by the air stream and a radiator fan O which is controlled by a ther moswitch The lower the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect gt a E LH er gt j X WE wan yi Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water 15 COOLING SYSTEM Warning 143 Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed con tact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Condition The engine is cold Stand the motorcycle upright on a horizontal surface Remove the cap of the compensating tank O Check the coolant antifreeze 25 45
96. ntly The speed RPM 2 must always be higher than the speed RPM 1 Set the speed with the MODE and SET buttons e Info The MODE button increases the value The SET button decreases the value Do not activate the two buttons for approx 15 seconds Y The display RPM 2 goes out and the set speed is stored Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if overfilled Follow the instructions on refueling 6 CONTROLS 50 1 Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that has been contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Lift the cover o of the filler
97. ntually wear out during operation If the rubber dampers are not changed in time the rear sprocket carrier and the rear hub will be damaged Preparatory work WE ty S00678 10 Raise the motorcycle with the rear wheel stand p 77 Remove the rear wheel 4 p 111 Main work Check bearing O If the bearing is damaged or worn Change the bearing 4 Check the rubber dampers 2 of the rear hub for damage and wear If the rubber dampers of the rear hub are damaged or worn Change all rubber dampers in the rear hub Lay the read wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub To check the play O hold the rear wheel tight and try to rotate the rear sprocket e Info Measure the play on the outside of the rear sprocket Play in rubber dampers rear wheel lt 5 mm lt 0 2 in f play A is larger than the specified value 13 WHEELS TIRES 118 Change all rubber dampers in the rear hub Finishing work Install the rear wheel 4 p 113 Take the motorcycle off of the rear wheel stand p 77 Check the chain tension p 84 13 6 Checking the tire condition 0 Warning Danger of accidents Uncontrollable vehicle handling in the event of a flat tire Inthe interest of safety replace damaged or worn tires immediately Your authorized KTM workshop will be glad to help Warning A Da
98. p may also light up if the rotating speeds of the front and rear wheels differ greatly under extreme riding conditions for example when making wheelies or if the rear wheel spins This causes the ABS to switch off To reenable the ABS the vehicle must be stopped and the ignition switched off The ABS is reenabled when the vehicle is switched on again The ABS warning lamp goes out when you start off Button o can be used to switch ABS off manually see Starting Warning Danger of accidents Reduced braking efficiency due to worn brake disc s Change the worn brake disc s without delay Your authorized KTM workshop will be glad to help Ae 400480 10 Check the thickness of the front and rear brake discs at several places on the disk to see if it conforms to measurement O e info Wear reduces the thickness of the brake disc in area O of the brake disc Brake discs wear limit Front 3 6 mm 0 142 in Rear 3 6 mm 0 142 in Ifthe brake disc thickness is less than the specified value Change the brake discs 4 12 BRAKE SYSTEM 97 Check the front and rear brake discs for damage cracking and deformation If the brake disc shows signs of damage cracking or deformation Change the brake discs 4 12 3 Checking the brake fluid level of the front brake Warning Danger of accidents Failure of the brake system Ifthe brake fluid level falls below the MIN mark
99. parts of the exhaust or intake system with parts other than those specified by the manufac turer 2 5 Safe operation Danger Al Danger of accidents Danger arising from the rider s judgement being impaired Do not operate the vehicle while under the influence of alcohol drugs and certain medications or physically or mentally impaired Danger Al Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch hot components such as exhaust system radiator engine shock absorber and the brake system Allow these components to cool down before starting work on them Only operate the vehicle when it is in perfect technical condition in accordance with ts 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 SAFETY ADVICE 12 Warning Risk of injury Missing or poor protective clothing presents an increased safety risk Wear protective clothing h
100. ring of the oil filter cover Mount oil filter cover Mount and tighten the screws Guideline Screw oil filter cover 125 Duke M5 8 Nm 5 9 Ibf ft Screw oil filter cover 200 Duke M5 8 Nm 5 9 Ibf ft A e Info B00776 10 Too little engine oil or poor quality engine oil results in premature wear to the engine 17 SERVICE WORK ON THE ENGINE 155 Remove the oil filler plug with the O ring from the clutch cover and fill up with engine oil Engine oil 1 51 1 6 qt External temper Engine oil ature 0 50 C SAE 15W 50 32 122 F p 181 External tempera Engine oil ture 10 40 C SAE 10W 40 14 104 F p 182 Install and tighten the oil filler plug with the O ring Danger Al Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight Finishing work Fit the front spoiler p 94 Check the engine oil level p 152 e Info Too little engine oil or poor quality engine oil results in premature wear to the engine 17 SERVICE WORK ON THE ENGINE 156 Main work Remove the oil filler plug o with the O ring from the clu
101. rings 1 compression ring 1 tapered compression piston ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with one rotary pump Primary transmission 22 72 Clutch Clutch in oil bath mechanically activated Transmission 6 gear claw shifted Transmission ratio 1st gear 12 34 2nd gear 15 31 21 TECHNICAL DATA 167 3rd gear 18 28 4th gear 21 26 5th gear 22 23 6th gear 24 22 Mixture preparation Electronically controlled fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V 230 W Spark plug BOSCH VR 5 NE Spark plug electrode gap 0 8 mm 0 031 in Spark plug BOSCH Super R6 VR 5 NEW Spark plug electrode gap 1 mm 0 04 in Cooling Water cooling permanent circulation of coolant by water pump Idle speed 1 450 1 550 rpm Starting aid Electric starter 21 1 2 200 Duke Design 1 cylinder 4 stroke engine water cooled Displacement 200 cm 12 2 cu in Stroke 49 mm 1 93 in Bore 72 mm 2 83 in Compression ratio 11 5 1 Control DOHC 4 valves controlled via cam lever chain drive Valve diameter intake 28 5 mm 1 122 in 21 TECHNICAL DATA 168 Valve diameter exhaust 24 mm 0 94 in Valve clearance intake cold 0 08 0 12 mm 0 0
102. se RR os 46 Light switch lle 24 Loading the vehicle llle 58 Motorcycle cleaning A Suty ER gk eed ade Rone a 157 raising with the front wheel stand 78 189 raising with the rear wheel stand o o 77 taking off of the front wheel stand 79 taking off of the rear wheel stand LL 77 Oil filter CHANING AA eee e ew Aet Neu a AE 152 Oil screen cleaning d arbe Mek arr RS Gedo oa E 152 Operating substances 0 0 0 0 cee eee KK KK 14 Owner s Manual 0 00 0 ee eee 13 Parking ti i ARAN oaks VE beds 68 Parking light bulb Gliangllg sta d are dat Ag EA 134 Passenger footrests 0 0 llle 53 Passenger seat mounting Ss xane iaa as ad 81 YEMOVING a ds ee RN Ea A iaa ap 80 Play in throttle cable adjusting ci See eB E WE wa eed 150 CHECKING maddest ates Rex AA MAS S TS 149 Preparing for use advice on first use JA kk kk ee ee 56 after Storage sergo xura k kula a d Ok delk ab n era dal ek 162 checks and maintenance when preparing for use 60 Protective clothing o o o oo ooo KK KK 12 INDEX R Rear hub rubber dampers CHECKING lt x a eee tra ee une ole Pid A ati s tae 117 Rear sprocket CHECKING ovario dln e ok kal ES 89 Rear wheel installing oe a Pe nb 113 REMOVING ati ole Gat a ad da whe 111 Ridilig o Sante a o D 63 Startiig oTf ii oh Ab ar til ect Rats 63 S Safe operat
103. splay briefly 6 CONTROLS 6 13 16 Range riding time menu Condition Alternative 1 e The ignition is on e The motorcycle is stationary Alternative 2 e The ignition is on e The motorcycle is moving Press the SET button briefly and repeatedly until the desired info display appears The range and the riding time are displayed in this menu e info I The range depends on the average fuel consumption and the fuel quantity in the fuel tank The range is displayed after several 100 meters of travel after the ignition is switched on If the ignition was switched off for over 60 minutes the display of the range and riding time is reset to O Press the SET button Next display mode on the info display briefly 6 CONTROLS 6 13 17 Total distance menu ODO 6 13 18 Distance menu 1 TRIP 1 45 Condition Alternative 1 e The ignition is on e The motorcycle is stationary Alternative 2 e The ignition is on e The motorcycle is moving Press the MODE button briefly and repeatedly until ODO appears on the display ODO shows the total distance covered e Info This value is retained even if the battery is disconnected and or the fuse blows Press the MODE but Next display mode on the display ton Condition Alternative 1 The ignition is on e The motorcycle is stationary Alternative 2 The ignition is on e The motorcycle is mov
104. sumers and the battery will discharge You should therefore always switch off the engine with the ignition key the emergency OFF switch is intended for emergencies only Park the motorcycle on a firm surface Swing the side stand forward with your foot as far as it will go and lean the vehicle on it Lock the steering by turning the handlebar fully to the left pressing down the ignition key to position amp and turning it to position lI To make the steering lock engage more easily move the handlebar a little to the left and right Remove the ignition key 8 RIDING INSTRUCTIONS 70 8 7 Transport Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Note Fire hazard Some vehicle components become very hot when the vehicle is operated Do not park the vehicle near flammable or explosive substances Do not place objects on the vehicle while it is still warm from being run Always let the vehicle cool first Switch off the engine and remove the ignition key S Use tension belts or other suitable devices to secure the motorcycle against accidents or falling over 401448 01 8 RIDING INSTRUCTIONS 71 8 8 Refueling Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot ve
105. t the negative cable of the battery to avoid damage to the onboard electron ics 14 ELECTRICAL SYSTEM 125 M00729 10 Main work Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 You can also use the battery charger to test rest potential and start potential of the bat tery and to test the alternator With this device you cannot overcharge the battery Info e Never remove lid O Charge the battery with a maximum of 10 of the capacity specified on battery housing Switch off the battery charger after charging and disconnect from the battery Guideline The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the 3 months motorcycle is not in use Position the negative cable and mount and tighten the screw Position the negative terminal cover Finishing work Mount the seat p 82 Mount the passenger seat p 81 Set the clock p 47 14 ELECTRICAL SYSTEM 126 14 4 Changing the ABS fuses Option With ABS 0 Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never bypass or repair fuses Info Two fuses for the ABS are located under the passenger seat These fuses protect the return pump and the hydraulic unit of the ABS The
106. taining bracket M5 6 Nm 4 4 Ibf ft Loctite 2437 Screw retaining bracket stator cable M5 8 Nm 5 9 Ibf ft Loctite 243 Screw stator M5 8 Nm 5 9 Ibf ft Loctite 243 Clutch cable retaining bracket screw M6 6 Nm 4 4 Ibf ft Loctite 243 125 Duke Clutch cable retaining bracket screw M6 6 Nm 4 4 Ibf ft Loctite 243 200 Duke Cylinder head screw M6 12 Nm 8 9 Ibf ft Engine sprocket screw 125 Duke M6 11 Nm 8 1 Ibf ft Engine sprocket screw 200 Duke M6 11 Nm 8 1 Ibf ft Nut water pump impeller M6 10 Nm 7 4 Ibf ft Loctite 243 Plug water pump drain hole M6 8 Nm 5 9 Ibf ft Screw alternator cover M6 12 Nm 8 9 Ibf ft Screw bearing retainer M6 12 Nm 8 9 Ibf ft Loctite 2437 Screw camshaft bearing bridge M6 11 Nm 8 1 Ibf ft 21 TECHNICAL DATA 170 Screw chain securing guide M6 11 Nm 8 1 Ibf ft Loctite 2437 Screw clutch cover M6 12 Nm 8 9 Ibf ft Screw engine case M6x40 12 Nm 8 9 Ibf ft Screw engine case M6x60 12 Nm 8 9 Ibf ft Loctite 2437 Screw freewheel gear retaining bracket M6 12 Nm 8 9 Ibf ft Loctite 2437 Screw locking lever M6 12 Nm 8 9 Ibf ft Loctite 2437 Screw oil pump M6 12 Nm 8 9 Ibf ft Loctite 2437 Screw retaining bracket shaft seal ring M6 11 Nm 8 1 Ibf ft Loctite 243 clutch cover Screw shift drum locating M6 12 Nm 8 9 Ibf ft Loctite 243
107. tch cover and fill up with engine oil Engine oil SAE 15W 50 p 181 Engine oil SAE 10W 40 p 182 e info For optimal performance of the engine oil do not mix different types of engine oil If appropriate change the engine oil Install and tighten the oil filler plug with O ring Danger Al Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight Finishing work Check the engine oil level 7 p 152 18 CLEANING CARE 157 18 1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high pressure cleaning equipment When cleaning the vehicle with a pressure cleaner do not point the water jet directly onto electrical components connectors cables bearings etc Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component Excessive pres sure can cause malfunctions or destroy these parts Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info If you clean the motorcycle regular
108. that have been approved and or recommended by KTM Service work and repairs must be performed properly Your authorized KTM workshop will be glad to help The ABS is a safety system that prevents locking of the wheels when the vehicle is traveling straight ahead without the action of lateral forces Warning Danger of accidents Vehicle rollover It is not always possible to prevent vehicle rollover in extreme riding situations e g luggage loaded with a high center of gravity varying road surfaces steep descents full braking without disengaging the gear Adapt your riding style to the road conditions and your riding ability The ABS operates with two independent brake circuits front and rear brakes During nor mal operation the brake system operates like a conventional brake system without ABS When the ABS control unit detects the tendency of a wheel to lock the ABS begins regu lating the braking pressure The control process causes the hand and foot brake levers to vibrate slightly 12 12 2 BRAKE SYSTEM Checking the brake discs 96 ABS warning lamp e must light up after the ignition is switched on and go out after start ing off If it does not go out after starting off or if it lights up while riding this indicates a fault in the ABS In this case the ABS is no longer enabled and the wheels may lock during braking The brake system itself stays functional only ABS control is not available The ABS warning lam
109. the brakes do not overheat Option With ABS Warning Danger of accidents Greater stopping distance due to ABS Braking should be appropriate to the driving situation and the road conditions Warning Danger of accidents Very forceful braking can cause the wheels to block ABS must be switched on to be effective When braking release the throttle and apply the front and rear brakes at the same time 8 8 6 RIDING INSTRUCTIONS 68 Info When ABS is active you can achieve maximum braking power even on low grip surfaces such as sandy wet or slippery ter rain without locking of the wheels 0 Warning Danger of accidents Locking of the wheels due to braking action of the engine Pull the clutch during emergency braking full brake application and when braking on a slippery surface Warning A Danger of accidents Road grip is reduced when braking with the motorcycle at an angle or on a laterally inclined surface Braking should be completed before you enter into a bend Braking should always be completed before you go into a bend Change down to a lower gear appropriate to your road speed On long downhill stretches use the braking effect of the engine Change down one or two gears but do not over rev the engine In this way you have to brake far less and the brakes do not overheat Stopping parking A Note Warning Risk of misappropriation Usage by unauthorized persons Never leave
110. this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to 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 viewer Ifthe brake fluid level is below the MINmarking Add front brake fluid 4 p 98 C00200 10 12 12 4 BRAKE SYSTEM 98 Adding front brake fluid A A A Warning Danger of accidents Failure of the brake system Ifthe brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles f brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the
111. torcycle with cold water and dry it well 18 CLEANING CARE 160 Treat the engine swingarm and all other bright and zinc plated parts except for the brake discs with a wax based corrosion inhibitor e Info Corrosion inhibitor is not permitted to come in contact with the brake discs as this would greatly reduce the braking force Clean the chain p 83 19 19 1 STORAGE Storage 161 Info If you want to garage the motorcycle for a longer period take the following steps Before storing the motorcycle check all parts for function and wear If service repairs or replacements are necessary you should do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season When refueling for the last time before taking the motorcycle out of service add fuel additive aN Fuel additive p 184 Refuel p 71 n at Clean the motorcycle p 157 Peg Change the engine oil and oil filter clean the oil screen 4 p 152 O O Check the antifreeze and coolant level p 142 401058 01 Check the tire air pressure p 119 Remove the battery 4 p 121 Recharge the battery 4 p 123 Guideline Storage temperature of battery without 0 35 C 32 95 F direct sunlight Store the vehicle in a dry location that is not subject to large fluctuations
112. ttery amp EU 121 14 2 Installing the battery amp E 122 14 3 Recharging the battery amp 123 14 4 Changing the ABS fuses Option With ABS 126 14 5 Changing the fuses of individual power CONSUMES asenne kak vv reni ve rone eae e rea ya da o ng 127 14 6 Changing the headlight bulb 131 15 16 17 19 20 5 14 7 Changing the parking light bulb 134 14 8 Checking the headlight setting 137 14 9 Adjusting the headlight range 138 COOLING SYSTEM 3 i tinte ene Etui ue dte k nek 141 15 1 Cooling system ooccccocnncnocnccocnncnnonoconinononinonons 141 15 2 Checking the antifreeze and coolant level 142 15 3 Checking the coolant level 144 15 4 Draining the coolant A 146 15 5 Filling bleeding the cooling system 147 TUNING THE ENGINE cseseseeeeceeeeceeeeeeeeeeaeeeeeeeess 149 16 1 Checking the play in the throttle cable 149 16 2 Adjusting the play in the throttle cable X 150 16 3 Checking the clutch lever play 150 16 4 Adjusting the clutch cable play 151 SERVICE WORK ON THE ENGINE Ml 152 17 1 Checking the engine oil level 152 17 2 Changing the engine oil and oil filter cleaning the oil screen ke 152 17 3 A
113. turn to the right Remove the key Y You can now steer the bike again 400731 01 6 CONTROLS 28 6 13 Combination instrument 5555550 6 13 1 Overview Display p 35 Function buttons p 33 Info display p 39 Indicator lamps p 34 AJ QI N 401685 10 6 CONTROLS 6 13 2 Activation and test 401686 01 29 Activation The combination instrument is activated when the ignition is switched on Test The segments of the tachometer and the gear display light up and switch off in sequence The speed display counts from O to 199 and back The remaining display segments outside the info display light up briefly The READY TO RACE gt gt logo appears on the info display The display then changes to the last selected mode 6 CONTROLS 6 13 3 Warning notes Low Oil Pressure appears on the info display if the oil pressure is too low Low Fuel Level appears on the info display if the fuel level reaches the reserve mark 30 6 CONTROLS the specified value 31 High Coolant Temperature appears on the info display if the coolant temperature rises above Coolant temperature 125 C 257 F Side Stand Down appears on the info display if the side stand is folded down Low Battery appears on the info display if the battery voltage falls below the specified value Battery voltage 10 80 V 6 CONTROLS
114. ut inner clutch hub M14LH 60 Nm 44 3 Ibf ft Loctite 243 Nut primary gear timing chain sprocket M14 55 Nm 40 6 Ibf ft Loctite 243 Oil drain plug M24x1 5 15 Nm 11 1 Ibf ft 21 3 Capacities 21 3 1 Engine oil Engine oil 1 51 1 6 qt External temperature O Engine oil SAE 15W 50 50 C 32 122 F p 181 External temperature 10 40 C 14 104 F Engine oil SAE 10W 40 p 182 21 TECHNICAL DATA 21 3 2 Coolant 172 Coolant 11 qt Coolant p 181 21 3 3 Fuel Total fuel tank capacity approx 11 2 9 US gal Super unleaded ROZ 95 RON 95 PON 91 p 183 Fuel reserve approx 1 51 1 6 qt 21 4 Chassis Frame Lattice frame of steel tubes powder coated Fork WP Suspension Shock absorber WP Suspension Brake system Front Disc brake with four pot brake caliper Rear Disc brake with single piston brake caliper floating Suspension travel Front 150 mm 5 91 in Rear 150 mm 5 91 in Brake discs diameter Option Without ABS Front 280 mm 11 02 in Rear 230 mm 9 06 in Brake discs diameter Option With ABS Front 300 mm 11 81 in Rear 230 mm 9 06 in 21 TECHNICAL DATA 173 Brake discs wear limit Front 3 6 mm 0 142 in Rear 3 6 mm 0 142 in Tire air pressure so
115. w cap with membrane e Info Clean up overflowed or spilt brake fluid immediately with water Option With ABS Stand the vehicle upright Remove screw cap o with membrane O Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 181 Refit screw cap with membrane e Info Clean up overflowed or spilt brake fluid immediately with water 12 10 Checking the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help 12 BRAKE SYSTEM 106 Note Danger of accidents Reduced braking efficiency caused by damaged brake discs Ifthe brake linings are not changed in time the steel brake lining carriers grind on the brake disc The braking effect is greatly reduced and the brake discs are destroyed Check the brake linings regularly Check the brake linings for minimum thickness O Minimum thickness gt 1 mm gt 0 04 in Ifthe minimum thickness is less than specified Change the rear brake linings 4 Check the brake linings for damage and cracking If there is wear or tearing Change the rear brake linings 4 M00006 10 13 13 1 WHEELS TIRES Removing the front wheel A B00743 10 107 Preparatory work Raise the motorcycle with the rear wheel stand p 77 Raise th
116. ycle is stationary Press the MODE button briefly and repeatedly until ODO appears on the display Press the MODE and SET buttons for 5 10 seconds Y The time display begins to flash Set the hours display using the MODE button Set the minutes display using the SET button Press the MODE and SET buttons for 5 10 seconds X The time is set 6 CONTROLS 6 13 22 Adjusting the shift speed RPM 1 6 13 23 Adjusting the shift speed RPM 2 48 Condition The ignition is on The motorcycle is stationary Press the MODE button briefly and repeatedly until TRIP 2 appears on the display Press the MODE button for 5 10 seconds Y The display RPM 1 appears e Info The engine speed can be set at intervals of 50 RPM 1 is the engine speed above which the shift warning light starts to flash Set the speed with the MODE and SET buttons e Info The MODE button increases the value The SET button decreases the value Do not activate the two buttons for approx 15 seconds Y The display RPM 1 goes out and the set speed is stored Condition The ignition is on The motorcycle is stationary 6 CONTROLS 49 Press the MODE button briefly and repeatedly until TRIP 2 appears on the display Press the SET button for 5 10 seconds Y The display RPM 2 appears e info The engine speed can be set at intervals of 50 RPM 2 is the engine speed above which the shift warning light lights up con sta

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