Vehicle fitness before embarking on journey Engine oil replacement leak detection - level checking.

Ensure in between upper (Max) and lower (Min) level mark.

SAE 20W50 of API, SL or above with JASO MA, MA1 or Ma2

Coolant level inspection Top up leak detection.

If less then top up with Coolant (mixed ready to use) through plug (A).

Coolant antifreeze ready to mix. Motul Inugel expert (Pre-mixed).

Fan switch on test.Fan switches ON at 96 degrees.Fan switches OFF at 88 degrees.

Accelerator & Clutch cable Freeness end terminals check at both ends.

Drive chain + Sprocket inspection for wear. Slack adjustment + lubrication. 20 link length 301.5 mm.

Battery age and charge level capacity + Charging confirmation from engine.

Tyre tread depth more than 2 mm

Functioning of all bulbs / locks / switches.

EMS system confirmation : All sensors + actuators confirmation with DTC tool.

Confirm functioning of all sensors & actuators of engine management system with the help of DTC tool.

Cold starting ability confirmation + drivability check.

Front fork oil level Leak detection if any. Steering play check adjust.

Brake oil level / Top up / Brakes effectiveness to confirm.Motul DOT-4

MinMax

A

Things to carry to keep vehicle fitter on journey

Part number. Qty MRP1 Spark plug JG351209 1 195.502 Clutch cable JG161201 1 180.50

3 Throttle cable. JG161200 1 118.004 Speed sensor cable. JG402400 1 416.005 Head light bulb DG201071 2 397.006 Brake pads : front JG131810 1 Set 118.00

7 Brake pads : rear DK151085 1 Set 201.508 Oil filter JG571014 1 74.009 Filter cover O ring JG571016 1 5.70

10 In line fuel filter JG171802 1 96.5011 Air filter element JG581004 1 274.5012 Front brake lever DJ191057 1 108.5013 Clutch lever comp JG161005 1 299.0014 Foot brake lever JG161004 1 234.50

15 Footrest Front RH JG113040 1 148.5016 Holder step RH JG113024 1 622.0017 Holder step LH JG113001 1 619.0018 Footrest Front LH JG113039 1 148.5019 Clutch friction plate 36JU0002 1 Set 772.50

20 Side stand switch JG401402 1 217.0021 Radiator Fan JG601400 1 1359.5022 Fork oil seal JG121013 1 394.50

Total 6996.70

Critical spare parts

SN Part description1 195.501 180.50

1 118.001 416.002 397.00

1 Set 118.00

Rs

1. Engine oil (20W50) : 518

2. Coolant / liter : 185

3. Chain spray 100 ml : 164

4. Dot 4 brake oil / 100 ml : 50

5. Fork oil Bottles (3) : 270

The Equipments.

1. Tyre pressure gauge. 1502. Foot pump. 3003. Puncture repair kit. 2754. First aid kit. 1505. Riding gear.6. Full face helmet.

The consumables.

Total 2062

The Essential documents.

1. Registration card.

2. Insurance note.3. Valid driving license.4. Permissions if any. 5. ID Proof

Engine does not crank when the Operating error Go through the steps of starting the engine.electric starter button is pressed

Battery discharged Recharge the battery

Fuse 1, 2, 3, or 4 blown Change the fuses of individual power consumers

No ground connection present Check the ground connection.

Engine turns only if the clutch lever The vehicle is in gear. Shift gear to neutral.is drawn The vehicle is in gear and the side Shift gear to neutral.

stand is folded out.

Engine turns but does not start Operating error. Go through the steps of starting the engine

Defect in fuel injection system Read out the fault memory using the KTM diagnostics tool.

Faults Possible cause Action

Simple Trouble shooting tips

Engine has too little power Air filter is very dirty. Change the air filter.

Fuel filter is very dirty. Check the fuel pressure.

Defect in fuel injection system. Read out the fault memory using the KTMdiagnostics tool.

Engine overheats Too little coolant in cooling system Check the cooling system for leakage.Check the coolant level.

Radiator fins very dirty Clean the radiator fins.

Foam formation in cooling system Drain the coolant Fill/bleed the cooling system

Thermostat defective Check the thermostat.

Fuse 5 blown Change the fuses of individual power consumers.

Defect in radiator fan system Check the radiator fan system.

The engine diagnosis warning lamp Defect in fuel injection system Read out the fault memory using the KTM(MIL) lights up red diagnostics tool.

Engine dies during the trip Lack of fuel Refuel

Fuse 1, 2, 3, or 4 blown Change the fuses of individual power consumers.

High oil consumption Engine vent hose bent Route the vent hose without bends or change it ifnecessary.

Engine oil level too high Check the engine oil level.

Engine oil too thin (low viscosity) Change the engine oil and oil filter, clean theoil screen.

Headlight and parking light not Fuse 6 blown Change the fuses of individual power consumers.functioning

Turn signal, brake light, and horn are Fuse 6 blown Change the fuses of individual power consumers.not functional

Time is not (correctly) displayed Fuse 2 blown Change the fuses of individual power consumers.Set the time.

Battery discharged Ignition not switched off when vehicle Recharge the battery.was parked.

Battery is not being charged by Check the charging voltage.alternator Check the open-circuit current.

Combination instrument shows Fuse 2 blown Change the fuses of individual power consumersnothing on the display Set the time.

Speedometer in combination Speedometer wiring harness isinstrument not functioning damaged or plug-in connection is Check the wiring harness and plug-in connection.

oxidized.

Faults Possible cause Action

Name Mobile No1 SHIEL AUTO AGRA Nirmal Kumar 9045600006

2 MANAN MOTORS LTD. AHMEDABAD Vikas Prajapati 96876772383 STANDARD MOTOR WORKS Aizawl BENJAMIN 9436143934

4 Doaba Automobiles Amritsar Mandeep Bhullar 99150118545 PAGARIYA AUTO CENTRE AURANGABAD Abhijeet Ghongade 99700530356 KHIVRAJ MOTORS BANGALORE Prasanna 98869910657 KHIVRAJ MOTORS BANGALORE Majeed 9343400529

8 AUTO SERVICE BANGALORE Babu 98867529369 A S MOTORS BARODA Mr. Devdutt Modi 9998222555

10 BELGAUM KTM BELGAUM Vasanth 988049342611 SURJEET AUTO AGENCIES BHOPAL Anwar Ali 9617931313

13 KVR MOTORS CALICUT Sharaj. K 773683686214 HIND MOTORS LTD. CHANDIGARH Pradeep Thakur 9780035622

15 SRI JAI AUTOS PVT. LTD. CHENNAI Sadagopan. P 984163727316 POPULAR MOTOR CORPORATION COCHIN George Williams 9567867174

17 SRI AUTOS COIMBATORE Mahesh Kumar. S 770881111718 MAYUR AUTO DEHRADUN Balfore 9411514770

19 T.C.SALUJA & SONS PVT. LTD FARIDABAD Jasdev 828507252020 Shiva Bajaj GHAZIABAD B M Singh 9654650449

21 SITARA MOTORS PVT.LTD GOA Raju 937027250722 KRISHNA AUTO SALES GURGAON Dalip Kumar 8826594753

23 SHREE AUTOMOBILES GUWAHATI ANUP 986470710324 MANIPUR MOTORS IMPHAL S TARAKANTA SINGH 9089485676

25 FRONTIER MOTORS JABALPUR Atul Asati 903946099226 P.L. MOTORS LTD. JAIPUR Vijaysingh Chouhan 9784789809

27 SOCIETY MOTORS Kanpur Atul Bajpai 923563679128 AUTO INDIA KOLHAPUR Shrikant Kalai 9370099200

29 PUSHPA SALES PVT. LTD. Lucknow Gajendra Tiwari 962155940030 DADA MOTORS LUDHIANA Hari Singh 9876039016

31 Globol Motors Mandi Yog Raj 962501368432 SUPREME AUTO DEALERS MANGALORE Shankar Bhat 9880077885

33 VIKRANT AUTOMOBILES MEERUT Neeraj Kumar 975670697034 SAI SERVICE AGENCY LTD. MUMBAI 9594952184

MUMBAI 77380607487259786273

3940

4142

4344

4546

4748

4950

5152

5354

55

WASAN & SONSGURU GOBIND AUTOMOBIES

BAGGA LINK SERVICE LTD.Dewan Motors

DEEWAN AUTOMOBILESSUMAN AUTOS

AAKASH AUTOMOBILES PVT LTDSAI SERVICE

VANDANA AUTO Shiva Bajaj

SRI VINAYAKA MOBIKES P.L.AHERKAR AUTOMOBILES

GUJARAT MOTORS PVT. LTD.SHREERAM BAJAJ

DEEDI AUTOMOBILESVARUN MOTORS

VARUN MOTORS

NASIKNavi Mumbai

NEW DELHINEW DELHI

NEW DELHINOIDA

PONDICHERRYPUNE

RAIPUR.SAHIBABAD

SECUNDRABADSOLAPUR

SURATTHANE

TRIVANDRUM VIJAYAWADA

VISHAKHAPATNAM

Prashant SansareMr. Gopal

Bijender SinghSuresh Bharadwaj

ShailendraSuresh Tomer

Senthil Kumar. VSandeep wagh

Mr.DeepakSudhir Kumar

Mr.SatyanarayanaA.Sheikh

Mr. Kiritsinh VaghelaBam

Lalu. AMr.Enok

Mr.Anand

95272544119702459138

99103991388860160266

98112562939971112432

73737199339923208197

94241117509311590323

98669440309922443661

97277126259324815438

98953819509885180334

9885922622

Mr. Amol

35 SHREERAM BAJAJ SANTOSH GIRNARE36 POPULAR MOTOR CORPORATION MYSORE Kiran

37 SRIVATSA INTERNATIONAL (P) LTD NAGERCOIL Chellam. S 960073643538 ARUN AUTOMOBILES NAGPUR R.Deshmukh 9579528100

Contact person details at Orange service network across India.Works Manager

SN Service centre Name Town

Exclusive Service Network as a backbone support for your journey

Largest network of dedicated workshops.

Factory trained Manpower.

Special tools & diagnostic equipments.

Genuine KTM / Kawasaki spare parts.

Supervised by KTM service Team.

Bon Voyage

62 Workshops across India.

Contact Us at info@ktmindia.com

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