20 TROUBLESHOOTING 101
Faults Possible cause Action
The engine does not turn when the
starter button is pressed
Operating error – Carry out the start procedure. ( p. 22)
Battery is discharged – Recharge the battery. ( p. 82)
– Check the charging voltage.
– Check the open-circuit current.
– Check the stator winding of the alternator.
Main fuse blown – Change the main fuse. ( p. 83)
Starter relay defective – Check the starter relay.
Starter motor defective – Check the starter motor.
Engine turns but does not start The plug-in connection of the fuel
hose connection is not connected
– Connect the plug-in connection of the fuel line.
Fuel screen in the fuel hose connec-
tion is clogged
– Change the fuel screen. ( p. 93)
Idle speed is not set correctly – Adjust the idle speed. ( p. 90)
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
0.8 mm (0.031 in)
Short circuit cable in wiring harness
frayed, kill switch defective
– Check the wiring harness. (visual check)
– Check the electrical system.
Defect in fuel injection system – Read out the fault memory using the KTM diag-
nostics tool.
Engine does not speed up Defect in fuel injection system – Read out the fault memory using the KTM diag-
nostics tool.
Engine has too little power Air filter is very dirty – Clean the air filter and air filter box.
( p. 52)
Fuel filter is very dirty – Change the fuel filter.
Defect in fuel injection system – Read out the fault memory using the KTM diag-
nostics tool.
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. ( p. 55)
Valve clearance too little – Adjust the valve clearance.
Engine dies during the trip Lack of fuel – Refuel. ( p. 26)
Engine overheats Too little coolant in cooling system – Check the cooling system for leakage.
– Check the coolant level. ( p. 86)
Too little air stream – Switch off the engine when standing.
Radiator fins very dirty – Clean radiator fins.
Foam formation in cooling system – Drain the coolant. ( p. 86)
– Refill the coolant. ( p. 87)
Bent radiator hose – Change the radiator hose.
Malfunction indicator lamp lights up
or 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.
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. 94)
Engine oil too thin (low viscosity) – Change the engine oil and oil filter and clean
the oil screens. ( p. 95)
Piston or cylinder worn – Measure the piston/cylinder mounting clear-
ance.
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