20 TROUBLESHOOTING 88
Faults Possible cause Action
The engine does not turn when the
starter button is pressed
Operating error – Carry out the start procedure. ( p. 21)
Battery is discharged –
Charge the battery. x ( p. 75)
–
Check the charging voltage. x
–
Check the quiescent current. x
–
Check the stator winding of the alternator. x
Main fuse blown – Change the main fuse. ( p. 76)
Starter relay defective –
Check the starter relay. x
Starter motor defective –
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. 81)
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
0.9 mm (0.035 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. 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. 49)
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. 50)
Valve clearance too little –
Adjust the valve clearance. x
Engine dies during the trip Lack of fuel – Refuel. ( p. 23)
Engine overheats Too little coolant in cooling system – Check the cooling system for leakage.
– Check the coolant level. ( p. 77)
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. x ( p. 78)
–
Refill the coolant. x ( p. 79)
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 connectors for corrosion and damage.
– 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. 82)
Engine oil too thin (low viscosity) – Change the engine oil and oil filter and clean
the oil screens. x ( p. 83)
Piston and cylinder worn – Piston/cylinder - determine the mounting clear-
ance.
Battery is discharged Battery is not charging –
Check the charging voltage. x
–
Check the stator winding of the alternator. x
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