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REPAIR MANUAL 2018
790 Duke
Art. no. 3206340en
INTRODUCTION
Read this repair manual carefully and thoroughly before beginning work.
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 model series. We reserve the right to make
changes in the interest of technical advancement without updating this repair manual at the same time.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop
are not specified here. It is assumed that the repair work will be performed by a fully trained mechanic.
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, deviations from figures and descriptions,
misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the
regular scope of supply.
© 2018 KTM Sportmotorcycle GmbH, Mattighofen Austria
Al I rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission
of the copyright owner.
ISO 9001(12 100 6061)
Wlt:JV
According to the international quality management standard ISO 9001, KTM uses quality assur-
--
ance processes that lead to the maximum possible quality of the products.
Issued by: TOV Management Service
REG.NO. 12 100 6061
KTM Sportmotorcycle GmbH
StallhofnerstraBe 3
5230 Mattighofen, Austria
This document is valid for the following models:
790 Duke EU (F9603R5, F9603R6)
790 Duke L EU (F9603R8)
I 1111111111111111 1111111111 1111111111111111 IIIIII II IIII
3206340en
04/2018
TABLE OF CONTENTS
1
MEANS OF REPRESENTATION ...................... 7
6.12
Changing the steering head bearing ... 36
1.1
Symbols used ....................................
6.13
Changing the steering damper ........... 37
7
6.14
Cleaning the dust boots of the fork
1.2
Formats used ..................................... 7
legs ................................................ 38
2
SAFETY ADVICE ............................................ 8
7
HANDLEBAR,CONTROLS ............................ 39
2.1
Repair Manual ................................... 8
7.1
Checking the free travel of the
2.2
Safety advice ..................................... 8
clutch lever ..................................... 39
2.3
Degrees of risk and symbols ................ 8
7.2
Setting the free travel of the clutch
2.4
Work rules ......................................... 8
lever ............................................... 39
3
IMPORTANT NOTES ...................................... 9
7.3
Changing the throttle grip ................. 40
3.1
Manufacturer and imp I ied warranty ...... 9
8
FRAME ...................................................... 45
3.2
Operating and auxiliary substances ...... 9
8.1
Checking the frame .......................... 45
3.3
Spare parts, accessories ..................... 9
3.4
Figures ............................................. 9
9
SHOCK ABSORBER, SWINGARM ................. 46
4
SERIAL NUMBERS ..................................... 10
9.1
Adjusting the spring preload of the
shock absorber ................................ 46
4.1
Type label ....................................... 10
9.2
Checking the heim joint for play ........ 46
4.2
Key number ..................................... 10
9.3
Removing the shock absorber ............ 47
4.3
Engine number ................................ 10
9.4
Installing the shock absorber ............. 48
4.4
Fork part number ............................. 10
9.5
Changing the heim joint. ................... 49
4.5
Shock absorber article number .......... 11
9.6
Removing the spring ......................... 51
4.6
Steering damper article number ........ 11
9.7
Installing the spring ......................... 52
5
MOTORCYCLE ............................................ 12
9.8
Removing the heim joint.. ................. 53
9.9
Installing the heim joint. ................... 54
5.1
Raising the motorcycle with the rear
9.10
Checking the swi ngarm ..................... 54
I ifti ng gear ...................................... 12
9.11
Checking the swingarm bearing for
5.2
Removing the rear of the motorcycle
play ................................................ 55
from the I ifti ng gear ......................... 12
9.12
Removing the swingarm .................... 55
5.3
Lifting the motorcycle with the front
9.13
Changing the swingarm bearing ......... 57
I ifti ng gear ...................................... 12
9.14
Installing the swingarm ..................... 61
5.4
Taking the motorcycle off the front
I ifti ng gear ...................................... 13
10
EXHAUST ................................................... 64
5.5
Raising the motorcycle with the work
10.1
Removing the main silencer .............. 64
stand .............................................. 13
10.2
Installing the main silencer ............... 64
5.6
Removing the motorcycle from the
10.3
Removing the exhaust system ............ 65
work stand ...................................... 14
5.7
Starting the vehicle .......................... 14
10.4
Installing the exhaust system ............ 67
5.8
Starting the motorcycle to check the
11
AIR FILTER ................................................ 71
function .......................................... 15
11.1
Removing the air filter ...................... 71
6
FORK, TRIPLE CLAMP ................................ 16
11.2
Installing the air filter ....................... 72
6.1
Removing the fork legs ..................... 16
11.3
Changing the air filter, cleaning the
6.2
Installing the fork legs ...................... 16
air filter box ..................................... 73
6.3
Disassembling the fork legs ............... 19
12
FUEL TANK, SEAT, TRIM ............................ 76
6.4
Removing the spring ......................... 21
12.1
Opening the fi Iler cap ....................... 76
6.5
Checking the fork legs ...................... 21
6.6
Installing the spring ......................... 22
12.2
Closing the filler cap ........................ 76
6.7
Assembling the fork legs ................... 23
12.3
Removing the passenger seat ............ 77
6.8
Checking the play of the steering
12.4
Mounting the passenger seat.. ........... 77
head bearing ................................... 26
12.5
Removing the front rider's seat.. ........ 78
6.9
Adjusting the steering head bearing
12.6
Mounting the front rider's seat.. ... ...... 78
play ................................................ 27
12.7
Removing the fuel tank ..................... 79
6.10
Removing the lower triple clamp ........ 28
12.8
Installing the fuel tank ..................... 81
6.11
Installing the lower triple clamp ........ 31
12.9
Removing front fender ...................... 84
2
TABLE OF CONTENTS
12.10 Installing front fender ....................... 84
14.6
Checking the charging voltage ......... 133
12.11 Checking the fuel pressure ................ 85
14.7
Checking the open-circuit current.. .. 133
12.12 Checking fuel pressure and
14.8
Changing the main fuse .................. 133
absorbing elements of the fuel tank
14.9
Changing ABS fuses ....................... 135
bracket ........................................... 89
14.10 Changing the fuses of individual
12.13 Changing the fuel tank sensor ........... 93
power consumers ........................... 136
12.14 Changing the fuel pump ................... 94
14.11 Diagnostics connector .................... 137
12.15 Changing the fuel filter ..................... 95
14.12 Front ACCl and ACC2 .................... 137
12.16 Refueling ...................................... 100
14.13 ACCl and ACC2 rear ...................... 137
13 WHEELS .................................................. 102
15
BRAKE SYSTEM ....................................... 138
13.1
Checking the tire pressure .............. 102
15.1
Checking the front brake linings ...... 138
13.2
Checking the tire condition ............. 102
15.2
Changing the front brake linings ...... 138
13.3
Checking the wheel bearing for
15.3
Adjusting the basic position of the
play .............................................. 103
hand brake lever ............................ 140
13.4
Checking the brake discs ................ 104
15.4
Checking the front brake fluid
13.5
Front wheel ................................... 105
level ............................................. 141
13.5.1
Removing the front wheel ........... 105
15.5
Adding front brake fluid .................. 141
13.5.2
Installing the front wheel ............ 106
15.6
Changing the front brake fluid ......... 142
13.5.3
Changing front wheel bearing ...... 107
15.7
Checking the rear brake Ii n i ngs ....... 144
13.5.4
Changing the front brake discs .... 109
15.8
Changing the rear brake linings ....... 145
13.6
Rear wheel .................................... 110
15.9
Checking the free travel of the foot
13.6.1
Removing the rear wheel using a
brake lever .................................... 147
work stand ................................ 110
15.10 Adjusting the basic position of the
13.6.2
Removing the rear wheel ............ 111
foot brake lever .............................. 148
13.6.3
Removing the rear wheel using a
15.11 Checking rear brake fluid level ........ 149
work stand ................................ 112
15.12 Adding rear brake fluid ................... 149
13.6.4
Installing the rear wheel ............. 113
15.13 Changing the rear brake fluid .......... 150
13.6.5
Changing the rear wheel
15.14 Bleeding the brake system .............. 152
bearing ..................................... 115
13.6.6
Changing the rear brake disc ....... 117
16
LIGHTING SYSTEM, INSTRUMENTS .......... 154
13.6.7
Checking the chain tension ......... 118
16.1
Programming the ignition key .......... 154
13.6.8
Adjusting the chain tension ........ 118
16.2
Loosening the headlight mask with
13.6.9
Checking the chain, rear
the head I ight ................................. 154
sprocket, engine sprocket, and
16.3
Mounting the headlight mask with
chain guide ............................... 119
the head I ight ................................. 155
13.6.10
Cleaning the chain ..................... 121
16.4
Removing the cover of the
13.6.11
Checking the rear hub rubber
headlight mask rack ....................... 155
dampers ................................... 122
16.5
Installing the cover of the headlight
13.6.12
Changing the rubber dampers in
mask rack ..................................... 156
the rear hub .............................. 123
16.6
Checking the head I ight setting ........ 157
13.6.13
Changing the bearing of the rear
16.7
Adjusting the headlight range .......... 158
sprocket carrier .......................... 123
16.8
Changing the rear turn signal .......... 158
13.6.14
Opening the chain ..................... 125
16.9
Changing the tail light .................... 163
13.6.15
Riveting the chain ...................... 125
13.6.16
Changing the drivetrain kit.. ........ 126
17
COMBINATION INSTRUMENT ................... 166
14 WIRING HARNESS, BATTERY .................... 129
17 .1
Combination instrument ................. 166
17.2
Activation and test ......................... 166
14.1
Removing the battery ..................... 129
17.3
Day-Night mode ............................. 166
14.2
I nsta 11 i ng the battery ...................... 130
17.4
Warning notes ................................ 167
14.3
Disconnecting the negative cable
17.5
Indicator lamps .............................. 167
of the battery ................................. 130
17.6
Display ......................................... 169
14.4
Connecting the negative cable of
17.7
TRACK display ............................... 170
the battery .................................... 131
17.8
Shift warning light ......................... 170
14.5
Recharging the battery ................... 131
17.9
Fuel level display ........................... 171
3
TABLE OF CONTENTS
17.10 Time ............................................. 171
17.11 Coolant temperature indicator ......... 171
17.12 Trip distance counter ..................... 172
17 .13 Setting the service interval
display .......................................... 172
17.14 Menu ............................................ 173
17.14.1
Favorites ................................... 173
17.14.2 Tripl ....................................... 173
17.14.3 Trip2 ....................................... 174
17.14.4 General Info .............................. 174
17.14.5
Settings .................................... 175
17.14.6
Bluetooth®(optional) .................. 175
17.14.7
Distance ................................... 175
17.14.8 Temp ........................................ 176
17.14.9
Pressure ................................... 176
17.14.10 Fuel Cons .................................. 176
17.14.11 Language .................................. 177
17.14.12 Clock/Date ................................ 177
17.14.13 DRL ......................................... 177
17.14.14 TPMS warning ........................... 178
17.14.15 Quick Selector 1 ........................ 179
17.14.16 QuickSelector2 ........................ 179
17.14.17 Set Favorites ............................. 180
17.14.18 Service ..................................... 180
17.14.19 Extra functions .......................... 180
17.14.20 Warnings ................................... 181
17.14.21 Ride Mode ................................ 181
17.14.22 Track ........................................ 181
17.14.23 Anti-wheelie mode ..................... 182
17 .14.24 Launch control .......................... 182
17.14.25 MTC + MSR .............................. 182
17.14.26 ABS .......................................... 183
17.14.27 ABS Mode ................................ . 183
17.14.28 Quick Shift+ ............................. 184
17.14.29 Shift Light ................................ 184
17.14.30 KTM MY RIDE (optional) ............ 184
17.14.31 Pairing(optional) ....................... 185
17 .14.32 Audio player (optional) ............... 186
17 .14.33 Telephony (optional) .................. 187
18 ENGINE .................................................. . 188
4
18.1
18.2
18.3
18.3.1
18.3.2
18.3.3
18.3.4
18.3.5
18.3.6
18.3.7
18.3.8
Removing the engine ...................... 188
Installing the engine ....................... 199
Engine disassembly ........................ 211
Clamping the engine into the
engine assembly stand ............... 211
Draining the engine oil ............... 211
Removing the oi I filter................ 212
Removing the starter motor......... 212
Removing the valve cover ............ 212
Removing shift shaft sensor ........ 213
Removing the gear position
sensor ....................................... 214
Removing the spacer .................. 214
18.3.9
Removing the alternator cover ..... 214
18.3.10
Removing the torque limiter and
starter idler gear . . . . . . . . . . . . . . . . . . . . . . . . 215
18.3.11
Removing the ignition pulse
generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
18.3.12
Removing the heat exchanger ...... 216
18.3.13
Removingthethermostat.. .......... 217
18.3.14
Removing the water pump
impeller .................................... 217
18.3.15
Removing the clutch cover .......... 218
18.3.16
Removing the clutch discs .......... 219
18.3.17
Removing the clutch basket.. ...... 219
18.3.18
Removing locking lever ............... 220
18.3.19
Removing the shift shaft... .......... 221
18.3.20
Removing the spark plugs ........... 221
18.3.21
Removing the camshafts ............. 222
18.3.22
Removing the cylinder head ........ 223
18.3.23
Removing the timing chain
rails .......................................... 224
18.3.24
Removing the rotor ..................... 225
18.3.25
Removing the oil pan ................. 226
18.3.26
Removing the oil pump unit.. ...... 227
18.3.27
Removing the engine case
downwards................................ 227
18.3.28
Removing the transmission
shafts ....................................... 229
18.3.29
Removing oil spray tube ............. 230
18.3.30
Removing the piston .................. 231
18.4
Working on individual parts ............. 232
18.4.1
Checking the radial clearance of
crankshaft bearings .................... 232
18.4.2
Changing the main bearing
shells ....................................... 233
18.4.3
Checking the balancer shaft ........ 235
18.4.4
Working on the upper section of
the engine case ......................... 235
18.4.5
Working on the lower section of
the engine case ......................... 238
18.4.6
Selecting the main bearing
shells ....................................... 238
18.4.7
Installing the primary gear .......... 239
18.4.8
Changing the shaft seal ring of
the water pump ......................... 239
18.4.9
Checking the radial clearance of
lower conrod bearing .................. 240
18.4.10 Changing the conrod bearing ....... 241
18.4.11
Cylinder-Nikasil®coating .......... 243
18.4.12
Checking/measuring the
cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
18.4.13
Checking/measuring the piston .... 244
18.4.14 Checking the piston ring end
gap ........................................... 245
18.4.15
Determining the piston/cylinder
mounting clearance .................... 245
18.4.16
Removing the oil pumps ............. 246
TABLE OF CONTENTS
18.4.17
Checking the oil pumps for
18.5.22
Installing the crankshaft
wear ......................................... 247
position sensor .......................... 294
18.4.18
Checking the oil pressure
18.5.23
Installing torque limiter and
regulator valve ........................... 248
starter idler gear ........................ 295
18.4.19
Installing the oil pumps .............. 249
18.5.24
Installing the alternator cover ...... 295
18.4.20
Preparing timing chain tensioner
18.5.25
Installing the spacer ................... 296
for installation ........................... 250
18.5.26
Installing the gear position
18.4.21
Checking the timing assembly ..... 251
sensor ....................................... 296
18.4.22
Working on the camshaft
18.5.27
Installing the shift shaft sensor ... 297
bearing bridge ........................... 252
18.5.28
Installing the valve cover ............ 298
18.4.23
Working on the cylinder head ...... 253
18.5.29
Installing the starter motor .......... 299
18.4.24
Checking the cylinder head ......... 258
18.5.30
Installing the oil filter ................. 299
18.4.25
Checking the clutch ................... 260
18.5.31
Installing the oil drain plug ......... 300
18.4.26
Removing the shift drum
18.5.32
Removing the engine from the
locating unit .............................. 261
engine assembly stand ............... 300
18.4.27
Checking the shift mechanism .... 262
18.4.28
Preassembling the shift shaft.. .... 263
19 CLUTCH ................................................... 301
18.4.29
Installing the shift drum
19.1
Adjusting the clutch release lever .... 301
locating unit .............................. 264
19.2
Checking the clutch ....................... 301
18.4.30
Disassembling the main shaft ..... 265
18.4.31
Disassembling the
20
SHIFT MECHANISM .................................. 309
countershaft .............................. 266
20.1
Checking the basic position of the
18.4.32
Checking the transmission .......... 267
shift lever ...................................... 309
18.4.33
Assembling the main shaft.. ........ 268
20.2
Adjusting the basic position of the
18.4.34
Assembling the countershaft.. ..... 269
shift lever ...................................... 309
18.4.35
Checking the electric starter
20.3
Changing the gear position sensor .... 309
drive ......................................... 271
20.4
Programming the gear position
18.4.36
Checking the freewheel .............. 272
sensor ........................................... 312
18.4.37
Working on the alternator cover ... 272
20.5
Changing the shift shaft sensor ....... 312
18.5
Engine assembly ............................ 273
20.6
Programming shift shaft sensor ....... 314
18.5.1
Installing the piston ................... 273
21
WATER PUMP, COOLING SYSTEM ............. 315
18.5.2
Installing the oil spray tube ......... 275
18.5.3
Installing the transmission
21.1
Checking the antifreeze and
shafts ....................................... 275
coolant level .................................. 315
18.5.4
Installing the lower engine
21.2
Checking the coolant level in the
case ......................................... 277
compensating tank ......................... 316
18.5.5
Installing the oil pump unit. ........ 279
21.3
Draining the coolant.. ..................... 317
18.5.6
Installing the oil pan .................. 280
21.4
Filling/bleeding the cooling
18.5.7
Installing the rotor ..................... 281
system .......................................... 317
18.5.8
Installing the timing chain rails ... 282
21.5
Changing the coolant ...................... 318
18.5.9
Installing the cylinder head ......... 282
22
LUBRICATION SYSTEM ............................. 321
18.5.10
Installing the camshafts ............. 284
18.5.11
Checking the valve clearance ...... 287
22.1
Oil circuit ...................................... 321
18.5.12
Adjusting the valve clearance ...... 288
22.2
Checking the engine oil level ........... 321
18.5.13
Installing the spark plugs ............ 289
22.3
Checking the engine oil pressure ..... 322
18.5.14
Installing the shift shaft ............. 289
22.4
Changing the engine oil and oil
18.5.15
Installing the locking lever .......... 290
filter, cleaning the oil screens ......... 324
18.5.16
Installing the clutch basket ......... 290
22.5
Adding engine oil ........................... 326
18.5.17
Installing the clutch discs ........... 291
22.6
Checking/cleaning the oil nozzle for
clutch lubrication ........................... 327
18.5.18
Installing the clutch cover .......... 292
18.5.19
Mounting the water pump
23
IGNITION SYSTEM .................................... 331
cover ........................................ 293
23.1
Alternator - checking the stator
18.5.20
Installing the thermostat.. ........... 293
winding ......................................... 331
18.5.21
Installing the heat exchanger ...... 294
23.2
Ignition coil - checking the primary
winding ......................................... 333
5
TABLE OF CONTENTS
23.3
Changing the spark plugs ................ 334
33
SPECIAL TOOLS ....................................... 396
24 CYLINDER HEAD ...................................... 340
34 STANDARDS ............................................ 412
24.1
Checking the valve clearance .......... 340
35
INDEX OF SPECIAL TERMS ....................... 413
24.2
Adjusting the valve clearance .......... 350
36
LIST OF ABBREVIATIONS .......................... 414
25 THROTTLE VALVE BODY ........................... 352
37
LIST OF SYMBOLS .................................... 415
25.1
Performing the initialization run ...... 352
25.2
Resetting the service display using
the KTM diagnostic tool .................. 352
37.1
Red symbols .................................. 415
37.2
Yellow and orange symbols .............. 415
37.3
Green and blue symbols .................. 415
26 TECHNICAL DATA ..................................... 353
INDEX ............................................................. 416
26.1
Engine .......................................... 353
26.2
Tolerance, engine wear limits .......... 354
26.3
Engine tightening torques ............... 355
26.4
Capacities ..................................... 358
26.4.1
Engine oil ................................. 358
26.4.2
Coolant ..................................... 358
26.4.3
Fuel ......................................... 358
26.5
Chassis ......................................... 358
26.6
Electrical system ............................ 359
26.7
Tires ............................................. 359
26.8
Fork .............................................. 359
26.9
Shock absorber .............................. 359
26.10 Chassis tightening torques .............. 360
27
CLEANING/PROTECTIVE TREATMENT ........ 364
27.1
Cleaning the motorcycle ................. 364
27.2
Checks and maintenance steps for
winter operation ............................. 365
28 STORAGE ................................................. 366
28.1
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
28.2
Preparing for use after storage ......... 367
29
SERVICE SCHEDULE ................................ 368
29.1
Additional information .................... 368
29.2
Required work ............................... 368
29.3
Recommended work ....................... 369
30 WIRING DIAGRAM .................................... 370
30.1
Page 1 of 11 ................................. 370
30.2
Page 2 of 11 ................................. 372
30.3
Page 3 of 11 ................................. 374
30.4
Page 4 of 11 ................................. 376
30.5
Page 5 of 11 ................................. 378
30.6
Page 6 of 11 ................................. 380
30.7
Page 7 of 11 ................................. 382
30.8
Page 8 of 11 ................................. 384
30.9
Page 9 of 11 ................................. 386
30.10 Page 10 of 11 ............................... 388
30.11 Page 11 of 11 ............................... 390
31
SUBSTANCES .......................................... 392
32 AUXILIARY SUBSTANCES ......................... 394
6
MEANS OF REPRESENTATION
1
1.1
Symbols used
The meaning of specific symbols is described below.
✓
Indicates an expected reaction (e.g. of a work step or a function).
X
Indicates an unexpected reaction (e.g. of a work step or a function).
Indicates a page reference (more information is provided on the specified page).
•
Indicates information with more details or tips .
I
»
Indicates the resu It of a testing step.
V
Indicates a voltage measurement.
A
Indicates a current measurement.
0
Indicates a resistance measurement.
Indicates the end of an activity including potential rework.
1.2
Formats used
The typographical formats used in this document are explained below.
Proprietary name
Name®
Brand™
Underlined terms
Indicates a proprietary name.
Indicates a protected name.
Indicates a brand available on the open market.
Refer to technical details of the vehicle or indicate technical terms, which
are explained in the glossary.
7
2 SAFETY ADVICE
2.1
Re~air Manual
Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips
that will help you repair and maintain your vehicle.
This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are
available.
2.2
Safe~ advice
A number of safety instructions need to be followed to operate the product described safely. Therefore read this
instruction and al I further instructions included carefu I ly. The safety instructions are high I ighted in the text and
are referred to at the relevant passages.
2.3
m
Note
Info
Various information and warning labels are attached in prominent locations on the product described. Do
not remove any information or warning labels. If they are missing, you or others may not recognize dangers
and may therefore be injured.
Degrees of risk and symbols
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the
appropriate measures are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not
taken.
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are
not taken.
Note
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
2.4
Work rules
Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered
using the number in parentheses. Example: bearing puller (15112017000)
During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts, seals,
sealing rings, 0-rings, pins, and lock washers).
In the case of certain screws, a thread locker (e.g. Loctite®) is required. Apply according to the manufacturer's
instructions.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged
or worn parts.
After completing a repair or service work, check the operating safety of the vehicle.
8
IMPORTANT NOTES 3
3.1
Manufacturer and iml)lied warranw
The work specified in the service schedule may only be performed in an authorized KTM workshop and must be
recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will
become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not
covered by the warranty.
Additional information on the manufacturer or implied warranty and the procedures involved can be found in the
Service & Warranty Booklet.
3.2
Ol)erating and auxilia
substances
Note
Environmental hazard
Improper handling of fuel is a danger to the environment.
-
Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use the operating and auxiliary substances (such as fuel and lubricants) as specified in the manual.
3.3
Only use spare parts and accessories approved and/or recommended by KTM. KTM accepts no liability for other
products and any resulting damage or loss.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4
Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not
always necessary to disassemble the component to perform the activity in question. Please follow the instructions
in the text.
9
4 SERIAL NUMBERS
4.1
TyP.e label
4.2
Key number
''
i
01
1234--+-
6
I
I
4.4
10
KEYCODECARD
V0 1200-10
En ine number
/0~
©
~ I \
H01047-10
Fork P.art number
402295-1 0
The type label Europe O is located on the steering head on the
left.
Type label Australia @ is located on the frame behind the steer-
ing head at the top left.
The key number O can be found on the KEYCOOECARO.
Info
You need the key number to order a spare key. Keep
the KEYCOOECARO in a safe place.
The engine number O is stamped onto the engine case at the
top.
The fork part number O is stamped on the inner side of the fork
stub.
SERIAL NUMBERS 4
4.5
Shock absorber article number
Shock absorber article number O is on the left side of the shock
absorber.
Steering damper article number
0
H02669-10
Steering damper article number O is embossed on the underside
of the steering damper.
11
5 MOTORCYCLE
5.1
Raising the motorcycle with the rear lifting gear
Note
Danger of damage
The parked vehicle can roll away or fall over.
-
Park the vehicle on a firm and level surface.
5.2
Note
402346-01
-
Mount the supports of the lifting gear.
-
Insert the adapter in the rear lifting gear.
Universal V adapter with bushings (63529955000)
(ml p. 405)
Rear wheel work stand (69329955000) (~R p. 405)
-
Stand the motorcycle upright, align the lifting gear with the
swingarm and the adapters, and lift the motorcycle.
Removing the rear of the motorcycle from the lifting gear
Danger of damage
The parked vehicle can roll away or fall over.
-
Park the vehicle on a firm and level surface.
-
Secure the motorcycle against falling over.
-
Remove the rear lifting gear and lean the vehicle on side
stand O.
402029-1 0
5.3
Liftin the motorcycle with the front liftin
ear
Note
Danger of damage
The parked vehicle can roll away or fall over.
-
Park the vehicle on a firm and level surface.
402344-01
12
Preparatory work
-
Raise the motorcycle with the rear lifting gear. (lei®. p. 12)
Main work
-
Move the handlebar to the straight-ahead position. Align the
lifting gear at the front with the adapters to the fork legs.
I Front wheel work stand, small (61129965100) (!2~ p. 401)
•
Info
I
Always raise the motorcycle at the rear first.
-
Lift the motorcycle at the front.
41
41
MOTORCYCLE 5
5.4
Taking the motorcycle off the front lifting gear
Note
Danger of damage
The parked vehicle can roll away or fall over.
-
Park the vehicle on a firm and level surface.
-
Secure the motorcycle against falling over.
-
Remove the front lifting gear.
3 12029-10
5.5
Raising the motorcycle with the work stand
Note
Danger of damage
The parked vehicle can roll away or fall over.
-
Park the vehicle on a firm and level surface.
D05235-10
-
Remove plug O.
-
Take the cables out of the holders.
Remove cable holder 8.
-
Mount the special tool.
I Work stand (62529055200) (~ p. 403)
-
Position the motorcycle upright, align the special tool, and
raise the motorcycle.
41
13
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