KTM 1190 RC8 R EU/UK 2009 Operating instructions

REPAIR MANUAL 2009
1190 RC8 R EU/UK
1190 RC8 R AUS
1190 RC8 R FR
1190 RC8 R JP
Article no. 3206077en
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INTRODUCTION 1
INTRODUCTION
Read this repair manual carefully and thoroughly before beginning work.
Only use ORGINAL KTM SPARE PARTS.
The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly and properly.
This repair manual was written to correspond to the latest state of this series. We reserve the right to make changes in the interest of
technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop will not be specified
here. It is assumed that the repair work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not form part of the regular scope of delivery.
© 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
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CONTENTS 2
CONTENTS
MEANS OF REPRESENTATION ............................................ 6
IMPORTANT NOTES............................................................ 7
LOCATION OF SERIAL NUMBERS ........................................ 8
Vehicle identification number/type label ............................ 8
Key number .................................................................... 8
Engine number................................................................ 8
Fork part number............................................................. 8
Shock absorber part number............................................. 8
Steering damper part number ........................................... 9
MOTORCYCLE................................................................... 10
Jacking up motorcycle front............................................ 10
Taking front of motorcycle off work stand......................... 10
Jacking up the motorcycle in the middle (screw-in type).... 10
Removing the motorcycle from the work stand (screw-in
type) ............................................................................ 11
Jacking up the motorcycle in the middle (insertable
type) ............................................................................ 12
Removing the motorcycle from the work stand (insertable
type) ............................................................................ 12
Jacking up motorcycle at the rear.................................... 13
Taking the rear from the workstand ................................. 13
Starting ........................................................................ 13
01/FORK, TRIPLE CLAMP.................................................. 15
Adjusting the compression damping of the fork ................ 15
Adjusting the rebound damping of the fork....................... 15
Adjusting the spring preload of the fork ........................... 16
Bleeding fork legs.......................................................... 16
Vehicle level ................................................................. 17
Adjusting front vehicle level............................................ 17
Removing the fork ......................................................... 18
Installing the fork .......................................................... 19
performing a fork service ................................................ 21
Disassembling the fork legs ............................................ 21
Disassembling the outer tubes ........................................ 24
Checking the fork legs.................................................... 25
changing the lower DU bush........................................... 26
Assembling the outer tubes ............................................ 27
Assembling the fork legs ................................................ 27
02/HANDLEBAR, CONTROLS AND INSTRUMENTS.............. 32
Adjusting basic position of clutch lever............................ 32
Adjusting the steering damper ........................................ 32
Adjusting the handlebar height ....................................... 32
Adjusting the play in the throttle cable ............................ 33
Throttle grip.................................................................. 34
Changing the throttle grip............................................... 34
Adjusting the throttle cable at the throttle valve................ 37
03/FRAME........................................................................ 40
Side stand switch .......................................................... 40
Footrest position............................................................ 40
Adjusting footrest position.............................................. 40
Rear frame position ....................................................... 41
Adjusting the rear frame position .................................... 41
04/SHOCK ABSORBER, SWINGARM................................... 44
Adjusting the low-speed compression damping of the
shock absorber .............................................................. 44
Adjusting the high-speed compression damping of the
shock absorber .............................................................. 44
Adjusting the rebound damping of the shock absorber....... 45
Adjusting the spring preload of the shock absorber ........... 45
Adjusting the vehicle level at the rear .............................. 46
Removing the shock absorber ......................................... 46
Installing the shock absorber .......................................... 47
Servicing the shock absorber .......................................... 48
Removing the spring ...................................................... 48
Disassembling the damper ............................................. 49
Disassembling the piston rod.......................................... 50
Checking the damper..................................................... 51
Assembling the piston rod .............................................. 52
Assembling the damper.................................................. 53
Bleeding and filling the damper ...................................... 55
Filling the damper with nitrogen ..................................... 58
Installing the spring....................................................... 59
Removing the heim joint ................................................ 59
Installing the heim joint ................................................. 60
05/EXHAUST .................................................................... 62
Lambda sensor.............................................................. 62
Lambda sensor heater.................................................... 62
Removing the exhaust cover completely........................... 63
Installing the exhaust cover completely............................ 63
Removing the exhaust system ......................................... 63
Installing the exhaust system.......................................... 65
06/AIR FILTER.................................................................. 67
Removing the air filter ................................................... 67
Installing the air filter .................................................... 67
Removing the filter box bottom ....................................... 67
Installing the filter box bottom........................................ 68
07/FUEL TANK, SEAT, TRIM.............................................. 70
Removing the seat......................................................... 70
Fitting the seat.............................................................. 70
Removing the passenger seat.......................................... 70
Mounting the passenger seat .......................................... 70
Dismounting the fuel tank .............................................. 70
Installing the fuel tank................................................... 71
Removing the fuel tank guard ......................................... 72
Installing the fuel tank guard.......................................... 73
Checking the fuel pressure ............................................. 73
Checking the fuel pressure during the actuator test........... 74
08/MASK, FENDER, DECAL ............................................... 75
Removing the side covers ............................................... 75
Installing the side covers................................................ 75
Removing the inside cover.............................................. 75
Installing the inside cover .............................................. 76
09/FRONT WHEEL ............................................................ 77
Removing the front wheel............................................... 77
Installing the front wheel................................................ 77
Checking the tire condition............................................. 78
Checking the tire pressure.............................................. 79
Checking the front brake discs........................................ 80
10/REAR WHEEL .............................................................. 81
Removing the rear wheel ................................................ 81
Installing the rear wheel................................................. 81
Installing the rear wheel - when installing the engine ........ 82
Checking the rear brake disc........................................... 83
Checking for chain dirt................................................... 83
Cleaning the chain......................................................... 84
Checking the chain tension ............................................ 84
Adjusting the chain tension ............................................ 85
Checking rear sprocket / engine sprocket for wear ............. 85
Checking chain wear...................................................... 86
Checking chain sliding guard.......................................... 86
Checking rear hub cush drive.......................................... 86
11/WIRING HARNESS, BATTERY ....................................... 88
Electric starter lock control unit ...................................... 88
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CONTENTS 3
Fuel pump relay ............................................................ 88
Removing the battery..................................................... 88
Installing the battery...................................................... 89
Recharging the battery ................................................... 90
Changing the main fuse ................................................. 91
Changing the fuses of individual power consumers............ 91
13/BRAKE SYSTEM........................................................... 93
Brake linings................................................................. 93
Checking the front brake linings...................................... 93
Changing the front brake linings ..................................... 93
Checking the front brake fluid level ................................. 95
Adding front brake fluid ................................................. 95
Adjusting the basic position of the hand brake lever.......... 96
Checking the rear brake linings....................................... 96
Changing the rear brake linings....................................... 97
Checking the rear brake fluid level .................................. 99
Adding rear brake fluid .................................................. 99
Adjusting the foot brake pedal stub ............................... 100
Adjusting the foot brake pedal ...................................... 100
Removing the rear brake system.................................... 101
Installing the rear brake system .................................... 101
14/LIGHT SYSTEM, INSTRUMENTS ................................. 102
Immobilizer control unit............................................... 102
Activating/deactivating ignition key ............................... 102
Activating the ICU ....................................................... 104
Combination instrument - Activation of the
BOOTLOADER mode.................................................... 105
Updating the combination instrument software............... 105
Setting ROAD or RACE mode........................................ 106
Setting the clock with SET CLOCK ................................ 106
Adjusting shift speed RPM1/2 ...................................... 106
Setting the blank time of the LAP button
LAP BLANK T ............................................................. 107
Setting the number of laps SET NUM LAPS................... 107
Setting the fuel reserve display TRIPF RESET ................ 108
Setting the kilometers/miles SET KM/MILES.................. 108
Setting the temperature unit SET °C/°F ......................... 109
Switching the external temperature display on/off ........... 109
Resetting service display .............................................. 110
Checking the headlight setting...................................... 110
Adjust the headlight range............................................ 111
Changing the parking light bulb .................................... 111
Changing the low beam bulb......................................... 112
Changing the high beam bulb ....................................... 113
30/ENGINE..................................................................... 115
Removing the engine ................................................... 115
Preparing the engine for installation .............................. 117
Installing the engine .................................................... 117
Setting the engine to ignition top dead center of the
rear cylinder................................................................ 120
Setting the engine to ignition top dead center of the
front cylinder .............................................................. 121
30/DISASSEMBLING THE ENGINE................................... 122
Clamping the engine into the engine work stand............. 122
Removing the engine bracket........................................ 122
Draining the engine oil................................................. 122
Removing the front valve cover ..................................... 123
Removing the rear valve cover....................................... 123
Setting the engine to ignition top dead center of the
rear cylinder................................................................ 123
Removing the starter motor .......................................... 124
Removing the oil filler tube .......................................... 124
Removing the heat exchanger ....................................... 124
Removing the rear timing chain tensioner ...................... 124
Removing the rear camshaft ......................................... 125
Removing the rear cylinder head ................................... 125
Removing the rear piston.............................................. 125
Setting the engine to ignition top dead center of the
front cylinder .............................................................. 126
Removing the front timing chain tensioner..................... 126
Removing the front camshafts ...................................... 126
Removing the front cylinder head.................................. 126
Removing the front piston ............................................ 127
Removing the generator cover ....................................... 127
Removing the ignition pulse generator ........................... 127
Removing the torque limiter and idler............................ 128
Removing the rotor ...................................................... 128
Removing the idler and timing chain on the left ............. 128
Removing the oil filter.................................................. 129
Removing the balancer shaft ........................................ 129
Removing the drive wheel of the balancer shaft .............. 129
Removing the gear position sensor ................................ 130
Removing the left suction pump ................................... 130
Removing the water pump wheel................................... 131
Removing the clutch cover ........................................... 131
Removing the idler and timing chain on the right............ 132
Removing the clutch facing .......................................... 132
Removing the outer clutch hub ..................................... 132
Removing the primary gear ........................................... 133
Removing the force pump ............................................ 133
Removing the shift shaft .............................................. 134
Removing the shift drum locating.................................. 134
Removing the locking lever........................................... 135
Removing the left engine case ...................................... 135
Removing the crankshaft.............................................. 135
Removing the middle suction pump .............................. 136
Removing the transmission shaft................................... 136
Removing the oil spray tube ......................................... 137
Removing the timing chain rails of the right engine case
section ....................................................................... 137
Removing the timing chain rails of the left engine case
section ....................................................................... 137
30/ENGINE - WORK ON INDIVIDUAL PARTS..................... 138
Work on the right section of the engine case .................. 138
Removing the main bearing of the right engine case
section ....................................................................... 139
Selecting the main bearing shells.................................. 140
Installing the right main bearing ................................... 140
Work on the left section of the engine case .................... 141
Removing the left main bearing .................................... 143
Installing the left main bearing ..................................... 143
Changing the conrod bearing ........................................ 144
Work on the clutch cover.............................................. 145
Changing the step bearing of the crankshaft................... 146
Checking the radial clearance of the bottom connecting
rod bearing ................................................................. 147
Checking/measuring the cylinder................................... 147
Checking/measuring the piston ..................................... 148
Checking the piston ring end gap .................................. 149
Checking the piston/cylinder mounting clearance............ 149
Work on the cylinder head ............................................ 149
Checking the cylinder head .......................................... 152
Work on the right idler ................................................. 153
Checking the timing assembly ...................................... 154
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CONTENTS 4
Preparing the timing chain tensioner for installation ....... 154
Checking the oil pressure regulator valve........................ 155
Checking the oil pumps................................................ 155
Checking the clutch..................................................... 156
Checking the shift mechanism...................................... 157
Preassembling the shift shaft........................................ 158
Dismantling the main shaft .......................................... 158
Dismantling the countershaft........................................ 159
Checking the transmission............................................ 160
Assembling the main shaft ........................................... 161
Assembling the countershaft......................................... 161
30/ASSEMBLING THE ENGINE ........................................ 163
Installing the timing chain rails of the left engine case
section ....................................................................... 163
Installing the timing chain rails of the right engine case
section ....................................................................... 163
Installing the oil spray tube .......................................... 164
Installing the transmission shaft ................................... 164
Installing the middle suction pump ............................... 165
Installing the crankshaft............................................... 165
Installing the left engine case....................................... 166
Installing the locking lever............................................ 167
Installing the shift drum locating .................................. 167
Installing the shift shaft ............................................... 167
Installing the force pump ............................................. 168
Installing the left suction pump .................................... 169
Setting the engine to ignition top dead center of the
rear cylinder................................................................ 169
Installing the primary gear............................................ 170
Installing the outer clutch hub...................................... 170
Installing the clutch facing........................................... 171
Installing the idler and timing chain on the right ............ 172
Installing the clutch cover ............................................ 172
Installing the water pump wheel ................................... 173
Installing the gear position sensor ................................. 173
Installing the drive wheel of the balancer shaft............... 173
Installing the balancer shaft ......................................... 174
Installing the idler and timing chain on the left .............. 174
Installing the oil filter .................................................. 175
Installing the rotor....................................................... 175
Installing the torque limiter and idler ............................ 176
Installing the ignition pulse generator............................ 176
Installing the generator cover........................................ 176
Installing the oil drain plug........................................... 176
Installing the rear piston .............................................. 177
Installing the rear cylinder head.................................... 178
Installing the rear camshaft.......................................... 179
Installing the rear timing chain tensioner....................... 179
Setting the engine to ignition top dead center of the
front cylinder .............................................................. 180
Installing the front piston ............................................. 180
Installing the front cylinder head................................... 182
Installing the front camshafts ....................................... 182
Installing the front timing chain tensioner...................... 183
Installing the heat exchanger........................................ 183
Installing the oil filler tube ........................................... 184
Installing the starter motor ........................................... 184
Checking the rear cylinder control time.......................... 184
Adjusting the rear cylinder control time ......................... 184
Checking the rear valve clearance ................................. 185
Adjusting the rear valve clearance ................................. 186
Checking the front cylinder control time ........................ 186
Adjusting the front cylinder control time ........................ 186
Checking the front valve clearance ................................ 187
Adjusting the front valve clearance................................ 188
Installing the front valve cover ...................................... 188
Installing the rear valve cover ....................................... 188
Mounting the engine bracket ........................................ 189
Dismounting the engine from the work stand.................. 189
31/SECONDARY AIR SYSTEM .......................................... 190
Exhaust air injection .................................................... 190
32/CLUTCH .................................................................... 191
Checking fluid level of hydraulic clutch ......................... 191
Correcting fluid level of hydraulic clutch........................ 191
34/SHIFT MECHANISM ................................................... 192
Adjusting shift lever stub.............................................. 192
Adjusting shift lever..................................................... 192
35/WATER PUMP, COOLING SYSTEM .............................. 194
Checking the coolant level............................................ 194
Checking the antifreeze................................................ 194
Removing the radiator.................................................. 195
Installing the radiator................................................... 195
Adding coolant/bleeding the cooling system ................... 196
Filling the cooling system compensating tank................. 197
36/CYLINDER HEAD........................................................ 198
Engine coolant temperature sensor cylinder 1 ................ 198
Engine coolant temperature sensor for cylinder 2............ 199
Checking the valve clearance........................................ 200
Adjusting the rear valve clearance ................................. 201
Adjusting the front valve clearance................................ 202
Checking the rear cylinder control time.......................... 202
Checking the front cylinder control time ........................ 202
Adjusting the rear cylinder control time ......................... 203
Adjusting the front cylinder control time ........................ 204
Removing the rear camshaft ......................................... 205
Installing the rear camshaft.......................................... 205
Removing the front camshafts ...................................... 206
Installing the front camshafts ....................................... 206
Installing the rear timing chain tensioner....................... 207
Installing the front timing chain tensioner...................... 207
38/LUBRICATION SYSTEM .............................................. 208
Oil circuit ................................................................... 208
Checking the engine oil level ........................................ 209
Changing the engine oil and filter, cleaning the oil
screens....................................................................... 209
Draining engine oil, cleaning oil screens ........................ 209
Removing the oil filter.................................................. 211
Installing the oil filter .................................................. 212
Filling up with engine oil.............................................. 212
Adding engine oil ........................................................ 213
Checking the engine oil pressure................................... 213
Removing the oil jet for the clutch lubrication ................ 215
Checking / cleaning the oil jet for clutch lubrication........ 216
Installing the oil jet for the clutch lubrication................. 216
39/IGNITION SYSTEM ..................................................... 218
Crankshaft position sensor............................................ 218
Ignition coil ................................................................ 218
41/THROTTLE VALVE BODY............................................. 219
Throttle position sensor circuit A................................... 219
Throttle position sensor circuit A - checking in the
"zero" position ............................................................. 219
Adjusting the position of the throttle position sensor in
circuit A ..................................................................... 220
Removing the throttle valve body to adjust ..................... 221
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CONTENTS 5
Reinstalling the throttle valve body when the
adjustments have been made........................................ 222
Throttle position sensor circuit B................................... 223
Manifold absolute pressure sensor................................. 223
Connecting the vacuum hand pump to the manifold
absolute pressure sensor .............................................. 224
Ambient air pressure sensor.......................................... 225
Injector ...................................................................... 225
Rollover sensor............................................................ 226
EFI control unit........................................................... 227
Requesting the EFI control unit activation code.............. 227
Coding the EFI control unit........................................... 227
Flashing the EFI control unit ........................................ 228
IMMOBILIZER BLINK CODE............................................. 229
ENGINE CONTROL TROUBLE CODE................................. 238
CONNECTOR OVERVIEW.................................................. 391
Motor drive circuit A connector AE ................................ 391
Connector AI............................................................... 391
Crankshaft position sensor connector AL........................ 391
Clutch switch, connector AL ......................................... 391
Throttle position sensor circuit A, connector AM ............. 391
Throttle position sensor circuit B, connector AM............. 392
Gear position sensor, connector AM............................... 392
Fuel pump connector AM ............................................. 392
Wheel speed sensor, connector AM ............................... 392
Connector AO.............................................................. 392
Diagnostic connection plug AP...................................... 393
Rollover sensor connector AP........................................ 393
Throttle position sensor circuit A, connector AR.............. 393
Throttle position sensor circuit B, connector AR ............. 394
Fuel pump connector AR.............................................. 394
Side stand switch, connector AR................................... 394
Ignition coil cylinder 1 connector AS ............................. 394
Ignition coil cylinder 2 connector AS ............................. 394
CAN bus terminating resistor connector AT .................... 395
Crankshaft position sensor, connector AT....................... 395
Clutch switch connector AT .......................................... 395
Engine coolant temperature sensor cylinder 1 connector
AX.............................................................................. 395
Throttle stepper motor circuit B, connector CA ............... 395
Lambda sensor cylinder 1, connector CA ....................... 396
Lambda sensor cylinder 2, connector CA ....................... 396
Lambda sensor cylinder 1, connector CE ....................... 396
Lambda sensor cylinder 2, connector CE ....................... 396
Secondary air valve connector CK.................................. 396
Connector CM ............................................................. 397
Connector CO.............................................................. 397
Connector CP .............................................................. 398
Connector CQ.............................................................. 398
Connector CU.............................................................. 398
Fuel evaporation valve connector DF.............................. 399
Secondary air valve connector DF.................................. 399
Electric starter lock control unit, connector DN .............. 399
Immobilizer control unit, connector DN ......................... 399
Electric starter lock control unit, connector DO............... 399
Immobilizer control unit, connector DO.......................... 400
Ambient air pressure sensor connector DP ..................... 400
Manifold absolute pressure sensor cylinder 1,
connector DP .............................................................. 400
Manifold absolute pressure sensor cylinder 2
connector DP .............................................................. 400
Injector cylinder 1 connector DQ................................... 400
Injector cylinder 2 connector DQ................................... 401
ICU antenna connector DV ........................................... 401
Fuel pump relay connector EB ...................................... 401
ICU antenna connector EL............................................ 401
Connector EQ.............................................................. 401
Connector ER.............................................................. 402
Connector ES .............................................................. 402
Connector ET .............................................................. 402
Combination instrument connector EV........................... 403
Exhaust air injection valve, connector FE ....................... 403
Fuel pump relay .......................................................... 404
CAN bus terminating resistor ........................................ 404
TECHNICAL DATA - ENGINE............................................ 405
Capacity - engine oil .................................................... 405
Capacity - coolant........................................................ 406
TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF
ENGINE ......................................................................... 407
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........ 409
TECHNICAL DATA - CHASSIS .......................................... 411
Lighting equipment ..................................................... 411
Capacity - fuel............................................................. 412
TECHNICAL DATA - FORK................................................ 413
TECHNICAL DATA - SHOCK ABSORBER ........................... 414
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 415
CLEANING/CONSERVATION............................................. 417
Cleaning motorcycle .................................................... 417
Conservation for winter operation .................................. 417
STORAGE ....................................................................... 419
Storage....................................................................... 419
Putting into operation after storage ............................... 419
SERVICE SCHEDULE....................................................... 420
Important service tasks to be carried out by an
authorized KTM-RC8 workshop. .................................... 420
Important service tasks to be carried out by an
authorized KTM-RC8 workshop. (as additional job) ......... 421
WIRING DIAGRAM .......................................................... 422
1 of 3......................................................................... 422
2 of 3......................................................................... 426
3 of 3......................................................................... 432
OPERATING SUBSTANCES.............................................. 436
AUXILIARY SUBSTANCES................................................ 438
SPECIAL TOOLS.............................................................. 440
STANDARDS................................................................... 452
INDEX ............................................................................ 453
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MEANS OF REPRESENTATION 6
Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Identifies a page reference (more information is provided on the specified page).
Formats used
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.
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IMPORTANT NOTES 7
Warranty
The work described in the service schedule must be carried out exclusively in an authorized KTM-RC8 workshop and confirmed in the
service record, since otherwise any warranty claim is meaningless. No warranty claim can be met for damage resulting from manipula-
tion and/or other changes to the vehicle.
Materials
The fuels, lubricants and other materials named in this repair manual must be used according to specifications.
Spare parts, accessories
Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other products and any
resulting damage.
You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com
Work rules
Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in
parentheses. Ex: valve spring mounter (59029019000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
If thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its
usage.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Following repairs or servicing, the vehicle must be checked for roadworthiness.
Notes/warnings
Pay close attention to the notes/warnings.
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are miss-
ing, you or others may not recognize sources of danger and may therefore be injured.
Grades of risks
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Repair manual
–Read this repair manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you
repair and service your motorcycle.
–This manual assumes that the necessary special KTM tools and workplace and workshop equipment are available.
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LOCATION OF SERIAL NUMBERS 8
3.1Vehicle identification number/type label
100654-10
The vehicle identification number is stamped on the frame behind the steering head
on the right.
The type label is on the frame above the vehicle identification number.
3.2Key number
700222-01
The key number Code number can be found on the KEYCODECARD.
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.
Use the orange programming key to activate and deactivate the black ignition
key. Keep the orange programming key in a safe place: it must only be used for
learning and programming functions.
3.3Engine number
100655-10
The engine number is stamped on the right side of the engine.
3.4Fork part number
100656-10
The fork part number is stamped on the inner side of the fork stub.
3.5Shock absorber part number
100657-10
The shock absorber part number is stamped on the upper part of the shock absorber
above the adjusting ring towards the rear.
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LOCATION OF SERIAL NUMBERS 9
3.6Steering damper part number
100658-10
The steering damper part number is stamped on the top of the steering damper.
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MOTORCYCLE 10
4.1Jacking up motorcycle front
Note
Danger of damage The parked vehicle can roll away or fall over.
–Always place the vehicle on a firm and even surface.
–Jack up the motorcycle at the rear. ( p. 13)
100679-10
–Move the handlebar to the straight-ahead position. Align the work stand at the front
with the adapters to the fork legs.
Front work stand (61029055300) ( p. 443)
Info
Always jack up the rear of the motorcycle first.
–Jack up the motorcycle at the front.
4.2Taking front of motorcycle off work stand
Note
Danger of damage The parked vehicle can roll away or fall over.
–Always place the vehicle on a firm and even surface.
–Secure the motorcycle against falling over.
–Remove the work stand from the front.
4.3Jacking up the motorcycle in the middle (screw-in type)
Note
Danger of damage The parked vehicle can roll away or fall over.
–Always place the vehicle on a firm and even surface.
200598-01
–Remove screw .
–Remove screws . Take off the footrest bracket.
200599-01
–Unplug connector of the brake light switch. Remove cable binder .
–Remove screw . Hang the brake fluid reservoir to the side.
–Remove screws . Hang the footrest bracket to the side.
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MOTORCYCLE 11
200600-01
–Screw the holder of the special tool all the way into the lower drill holes of the
footrest brackets. Select the required height and width of the work stand.
Work stand (62529055000) ( p. 447)
–Jack up the motorcycle.
Info
Check that the work stand is seated correctly.
4.4Removing the motorcycle from the work stand (screw-in type)
Note
Danger of damage The parked vehicle can roll away or fall over.
–Always place the vehicle on a firm and even surface.
200600-01
–Remove the motorcycle from the work stand and rest it on the side stand.
–Unscrew the holder of the special tool from the drill holes in the footrest brackets.
Remove the work stand.
Work stand (62529055000) ( p. 447)
200599-11
–Position the footrest bracket. Mount and tighten screws .
Guideline
Screw, front footrest
bracket
M8 25 Nm
(18.4 lbf ft)
Loctite®243™
–Position the brake fluid reservoir. Mount and tighten screw .
Guideline
Screw, brake fluid reser-
voir of rear brake
M5 5 Nm
(3.7 lbf ft)
Loctite®243™
–Plug in connector of the brake light switch. Secure the cable with cable
binder .
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MOTORCYCLE 12
200598-11
–Position the footrest bracket. Mount and tighten screws .
Guideline
Screw, front footrest
bracket
M8 25 Nm
(18.4 lbf ft)
Loctite®243™
–Position the shift rod. Mount and tighten screw .
Guideline
Screw, shift rod M6 12 Nm
(8.9 lbf ft)
Loctite®243™
4.5Jacking up the motorcycle in the middle (insertable type)
Note
Danger of damage The parked vehicle can roll away or fall over.
–Always place the vehicle on a firm and even surface.
200597-01
–Let the work stand engage in the opening of the swingarm pivot with the plastic
sleeve. Select the required height and width of the work stand.
Work stand (62529055000) ( p. 447)
–Jack up the motorcycle.
Info
Check that the work stand is seated correctly.
4.6Removing the motorcycle from the work stand (insertable type)
Note
Danger of damage The parked vehicle can roll away or fall over.
–Always place the vehicle on a firm and even surface.
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MOTORCYCLE 13
200597-01
–Remove the motorcycle from the work stand and rest it on the side stand.
–Remove the work stand.
Work stand (62529055000) ( p. 447)
4.7Jacking up motorcycle at the rear
Note
Danger of damage The parked vehicle can roll away or fall over.
–Always place the vehicle on a firm and even surface.
100680-10
–Insert the work stand adapter in the rear of the work stand.
Work stand adapter (61029055120) ( p. 442)
Work stand rear (61029055100) ( p. 442)
–Stand the motorcycle upright, align the work stand to the link fork and the
adapters, and jack up the motorcycle.
4.8Taking the rear from the workstand
Note
Danger of damage The parked vehicle can roll away or fall over.
–Always place the vehicle on a firm and even surface.
–Secure the motorcycle against falling over.
–Remove the work stand from the rear and lean the vehicle on the side stand.
4.9Starting
Danger
Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death.
–When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed
space without an effective exhaust extraction system.
Caution
Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
–Never operate the vehicle with a discharged battery or without a battery.
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MOTORCYCLE 14
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.
100677-10
–Press the emergency OFF switch into the position .
–Switch on the ignition by turning the black programming key to the position ON .
After you switch on the ignition, you can hear the fuel pump working for about
two seconds. The function test of the combination instrument is run at the
same time.
–Shift into neutral.
The green idling speed indicator lamp Nlights up.
–Press the electric starter button .
Info
Do not press the electric starter button until the function test of the combi-
nation instrument is finished.
When starting the engine, DO NOT apply the throttle. If you apply the throttle
during the starting procedure, the engine management shuts off the injec-
tors and the engine will not start.
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds
before trying again.
This motorcycle is equipped with a safety start system. You can only start
the engine if the transmission is in neutral or if the clutch is pulled when a
gear is engaged. If the side stand is folded down and you shift into gear and
release the clutch, the engine stops.
–Take the weight off the side stand and swing it upwards with your foot as far as it
will go.
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01/FORK, TRIPLE CLAMP 15
5.1Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
An optimally adjusted compression damping ensures that the fork does not compress too far and fast when you brake hard or
when the load shifts very fast. It gives the rider good feedback about the road conditions.
100682-10
–Turn adjusting screws clockwise until they stop.
Info
The adjusting screws are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
–Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping
Comfort 15 clicks
Standard 10 clicks
Sport 5 clicks
Full payload 5 clicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce sus-
pension damping.
5.2Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork rebound behavior.
An optimally adjusted rebound damping brakes the springing energy and enables a fast, vibration-free resetting of the fork to
the zero position.
100683-10
–Turn adjusting screws clockwise to the stop.
Info
The adjusting screws are located at the top end of the fork legs.
Adjust both fork legs to the same setting.
–Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
Comfort 15 clicks
Standard 10 clicks
Sport 5 clicks
Full payload 5 clicks
Info
Turn clockwise to increase suspension damping; turn counterclockwise to
reduce damping.
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01/FORK, TRIPLE CLAMP 16
5.3Adjusting the spring preload of the fork
Info
Spring preload determines the initial fork position.
The spring preload setting is optimal when it is set for the weight of the rider and that of any baggage and a passenger, and
thus ensures a compromise between maneuverability and stability.
100683-11
–Turn adjusting screws clockwise to the stop.
Info
The adjustment screws are located at the top end of the fork legs.
Adjust both fork legs to the same setting.
–Turn back counterclockwise by the number of turns according to the fork type.
Guideline
Spring preload - Preload Adjuster
Comfort 5 turns
Standard 5 turns
Sport 3 turns
Full payload 3 turns
Info
Turn clockwise to increase preload, turn counterclockwise to reduce spring
preload.
Changing the spring preload has no influence on the rebound damping
although the adjustment screws turn during the adjustment work. However,
you should also adjust the rebound damping when you alter the spring
preload.
5.4Bleeding fork legs
–Lean the motorcycle on the side stand.
100684-10
–Remove bleeder screws briefly.
Any excess pressure escapes from the interior of the fork.
–Mount and tighten bleeder screws.
Info
Perform this action on both fork legs.
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01/FORK, TRIPLE CLAMP 17
5.5Vehicle level
100693-01
Warning
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.
The vehicle level can be adjusted at the front by means of the fork leg clamp and at
the rear by the eccentric shaft.
The fork legs can be clamped at three positions in the triple clamps.
Upper triple clamp flush
with upper edge of fork legs
0 mm (0 in)
Upper triple clamp flush
with 1st ring of fork legs
2.5 mm (0.098 in)
Upper triple clamp flush
with 2nd ring of fork legs
(standard)
5 mm (0.2 in)
The infinitely variable frame height setting can be adjusted by turning the eccentric
shaft.
Frame height difference
HIGH -LOW
12 mm (0.47 in)
Maximum adjustment range
between HIGH -LOW
180°
5.6Adjusting front vehicle level
Warning
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.
100694-10
–Loosen screws on the lower triple clamp.
–Loosen screw on the upper triple clamp.
–Loosen screw of the handlebar stub.
Info
Loosen the screws far enough to prevent damage to the lacquer when the
fork legs are moved.
Make the adjustments first on one fork leg and then on the other. When the
screws of both fork legs are loosened, the vehicle sags toward the front.
100695-01
–Align the fork leg in the desired position by means of the fork rings.
Guideline
Upper triple clamp flush with upper
edge of fork legs
0 mm (0 in)
Upper triple clamp flush with 1st ring
of fork legs
2.5 mm (0.098 in)
Upper triple clamp flush with 2nd ring
of fork legs (standard)
5 mm (0.2 in)
Info
The standard adjustment is the setting that provides the best vehicle han-
dling. When the fork is compressed, the suspension setting changes, caus-
ing the vehicle to become more stable but also more difficult to handle.
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01/FORK, TRIPLE CLAMP 18
100694-11
–Tighten screw .
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
–Tighten screws .
Guideline
Screw, bottom triple clamp M8 15 Nm
(11.1 lbf ft)
–Tighten screw .
Guideline
Screw, handlebar stub M8 20 Nm
(14.8 lbf ft)
–Repeat the adjustment on the other fork leg.
Info
The vehicle level setting on both fork legs must be identical.
5.7Removing the fork
–Jack up the motorcycle in the middle (insertable type). ( p. 12)
–Clamp down the rear of the vehicle.
100719-10
–Remove the screws from both brake calipers.
–Press back the brake linings with a light lateral tilting of the brake calipers on the
brake disc. Pull the brake caliper carefully back from the brake discs and hang it to
the side.
Info
Do not pull the hand brake lever when the brake calipers are removed.
201056-10
–Loosen screws and .
–Unscrew screw about six turns and press your hand on the screw to push the
wheel spindle out of the axle clamp. Remove screw .
Warning
Danger of accidents Reduced braking efficiency 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.
201057-10
–Remove the screws on both sides of the fender . Take off the fender.
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