TROUBLESHOOTING 82
Faults Possible cause Action
The engine cannot be cranked (elec-
tric starter)
Operating error – Carry out the start procedure. ( p. 19)
Battery discharged –
Recharge the battery. x ( p. 68)
–
Check the charging voltage. x
–
Check the open-circuit current. x
–
Check the stator winding of the alternator. x
Main fuse burned out – Change the main fuse. ( p. 69)
Faulty starter relay –
Check the starter relay. x
Faulty starter motor –
Check the starter motor. x
Engine turns but does not start Coupling of fuel hose connection not
joined together
– Join the fuel hose connection.
Idle speed is not set correctly –
Adjust the idle speed. x ( p. 73)
Spark plug oily or wet – Clean and dry the spark plug, or change it if
necessary.
Electrode distance (plug gap) of spark
plug too wide
– Adjust the plug gap.
Guideline
Spark plug electrode gap
0.7 mm (0.028 in)
Short circuit cable in wiring harness
frayed, kill switch defective
– Check the wiring harness. (visual check)
– Check the electrical system.
Plug-in connector of EFI control
device, crankshaft position sensor,
fuel pump or ignition coil oxidized
– Clean the plug connection and treat it with
contact spray.
Defect in fuel injection system – Read out the fault memory using the KTM diag-
nostics tool. x
Engine does not speed up Defect in fuel injection system – Read out the fault memory using the KTM diag-
nostics tool. x
Engine has too little power Air filter is very dirty –
Clean the air filter and air filter box. x
( p. 42)
Fuel filter is very dirty –
Change the fuel filter. x
Defect in fuel injection system – Read out the fault memory using the KTM diag-
nostics tool. x
Exhaust system leaky, deformed or
too little glass fiber yarn filling in
main silencer
– Check exhaust system for damage.
– Change the glass fiber yarn filling of the main
silencer. x ( p. 43)
Valve clearance too little –
Adjust the valve clearance. x
Engine dies during the trip Lack of fuel – Refuel. ( p. 21)
Engine overheats Too little coolant in cooling system – Check the cooling system for leakage.
– Check the coolant level. ( p. 70)
Too little air stream – Switch off the engine when standing.
Radiator fins very dirty – Clean the radiator fins.
Foam formation in cooling system –
Drain the coolant. x ( p. 71)
–
Refill the coolant. x ( p. 71)
Bent radiator hose –
Change the radiator hose. x
FI warning lamp (MIL) lights
up/flashes
Defect in fuel injection system – Stop the motorcycle and identify the faulty part
using the blink code.
– Check the cabling for damage and the electri-
cal plug-in connections for corrosion and dam-
age.
– Read out the fault memory using the KTM diag-
nostics tool. x
High oil consumption Engine vent hose bent – Route the vent hose without bends or change it
if necessary.
Engine oil level too high – Check the engine oil level. ( p. 76)
Engine oil too thin (low viscosity) – Change the engine oil and oil filter, clean the
oil screen. x ( p. 76)
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