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KTM 690 DUKE AUS/UK 2009, Owner'S Manual, Page: 76 / 176

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KTM 690 DUKE AUS/UK 2009 Owner'S Manual Download Page 76

MAINTENANCE WORK ON CHASSIS AND ENGINE

74

Note

Danger of accidents

 

Reduced braking due to damaged brake discs.

–

If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly
reduced and the brake discs are destroyed.

100137-10

–

Check the brake linings for minimum thickness

.

Minimum thickness

≥

1 mm (

≥

0.04 in)

» If the minimum thickness is less than specified:

–

Change the front brake linings.

x

–

Check the brake linings for damage and cracking.
» If there is wear or tearing:

–

Change the front brake linings.

x

9.24

Checking free play of foot brake lever

Warning

Danger of accidents

 

Brake system failure.

–

If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can
fail due to overheating. Adjust free travel on foot brake pedal according to specifications.

Summary of Contents for 690 DUKE AUS/UK 2009

Page 1: ...OWNER S MANUAL 2009 690 DUKE EU 690 DUKE AUS UK 690 DUKE JP ART NO 3211370en...

Page 2: ......

Page 3: ...viations resulting from continuing devel opment and design of our motorcycles cannot however be completely excluded All specifications are non binding KTM Sportmotorcycle AG specifically reserves the...

Page 4: ...only with the express written permission of the copyright owner ISO 9001 12 100 6061 According to the international quality management standard ISO 9001 KTM uses quality assurance processes that lead...

Page 5: ...ombination instrument display 26 Combination instrument speedometer 27 Setting kilometers or miles 27 Combination instrument time 28 Setting the clock 28 Combination instrument display ODO 29 Combinat...

Page 6: ...ocket engine sprocket for wear 68 Checking chain wear 69 Checking brake discs 70 Adjusting basic position of handbrake lever 71 Checking the front brake fluid level 71 Adding front brake fluid x 72 Ch...

Page 7: ...anging the engine oil and filter cleaning the oil screens x 126 Draining the engine oil x 126 Removing the oil filter x 127 Installing the oil filter x 129 Cleaning the oil screens x 129 Filling up wi...

Page 8: ...hnical understanding In the interest of your own safety have these jobs done in an authorized KTM workshop There your motorcycle will be serviced optimally by specially trained experts using the speci...

Page 9: ...t roads can lead to above average wear of components such as the transmission train or the brakes For this reason it may be necessary to service or replace worn parts before the limit specified in the...

Page 10: ...mply with the manufacturer s specific advice on its usage Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear Change damaged or worn parts Fo...

Page 11: ...you can ensure that such problems and conflicts do not have to occur To protect the future of motorcycle sport make sure that you use your motorcycle legally display environmental consciousness and r...

Page 12: ...the appropriate measures are not taken Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken Owner s manual It is important that you read this o...

Page 13: ...11...

Page 14: ...VIEW OF VEHICLE 12 3 1 View of vehicle front left side 700132 01...

Page 15: ...VIEW OF VEHICLE 13 1 Combination instrument 2 Rear mirror 3 Clutch lever 4 Seat 5 Handrail 6 Front brake caliper 7 Left fuel tap 8 Shift lever 9 Engine number 10 Side stand...

Page 16: ...VIEW OF VEHICLE 14 3 2 View of vehicle rear right 700133 01...

Page 17: ...tch indicator switch horn button 3 Filler cap 4 Emergency OFF switch electric starter button 5 Hand brake lever 6 Chassis number type label 7 Rear brake caliper 8 Passenger footrests 9 Map Select swit...

Page 18: ...number is stamped on the right of the steering head The type label is on the right of the frame behind the steering head 4 2 Key number 100179 10 The key number can be found on the KEYCODECARD Info Y...

Page 19: ...MBERS 17 4 3 Engine number 700125 01 The engine number is stamped on the left side of the engine under the engine sprocket 4 4 Fork part number 700126 01 The fork part number is stamped on the inner s...

Page 20: ...LOCATION OF SERIAL NUMBERS 18 4 5 Shock absorber part number 700128 01 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring toward the rear...

Page 21: ...er is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 5 2 Hand brake lever 500018 01 The hand brake lever is fitted on the right side of the handlebar...

Page 22: ...light are switched on High beam on Light switch is turned upwards In this position the high beam and the tail light are switched on 5 4 Headlight flasher switch 500020 11 The headlight flasher switch...

Page 23: ...the central position after use Flasher light right on Flasher switch pressed to the right The flasher switch returns automatically to the central position after use To switch off the flasher light pr...

Page 24: ...on circuit is closed and the engine can be started Steering locked In this position the ignition circuit is interrupted and the steering locked The ignition key can be removed 5 8 Emergency OFF switch...

Page 25: ...lectric starter button in basic position Electric starter button pressed In this position the electric starter is actuated 5 10 Combination instrument 700116 01 The combination instrument is installed...

Page 26: ...aveled ODO trip master 1 TRIP 1 and trip mas ter 2 TRIP 2 Press the SET button to reset the trip master 1 function TRIP 1 and trip master 2 func tion TRIP 2 to 0 0 Button has no function 5 12 Combinat...

Page 27: ...ed indicator lamp lights up green The transmission is switched to idle High beam indicator lamp lights up blue High beam is switched on Temperature warning lamp lights up red Coolant has reached a cri...

Page 28: ...ents light up for a second as a function test 700119 01 LEnGTth Following the display function test the wheel circumference LEnGth is shown for one sec ond Info 1870 mm corresponds to the circumferenc...

Page 29: ...e speed is shown in kilometers per hour km h or in miles per hour Mph 5 16 Setting kilometers or miles Info If you change the unit the value ODO is retained and converted accordingly Making the settin...

Page 30: ...utton pressed until the display mode changes from Km h to Mph or from Mph to Km h Guideline Activation duration of MODE button 10 s 5 17 Combination instrument time 700115 01 The time is shown in area...

Page 31: ...ton pressed simultaneously The time is set 5 19 Combination instrument display ODO 700120 01 In the ODO display mode the total distance traveled is shown in kilometers or miles Info This value is reta...

Page 32: ...ng TRIP 2 Info The TRIP 2 trip counter is always running and counts up to 999 9 The trip counter can be used to measure the distance covered during trips or between two refueling stops After the value...

Page 33: ...F display the fuel warning light switches on 5 23 Combination instrument coolant temperature indicator 700124 01 The temperature display consists of 12 bars The more bars showing the hotter the coolan...

Page 34: ...sert the ignition key Turn the ignition key 90 counterclockwise and remove the filler cap Info The filler cap has a tank air vent system 5 25 Closing filler cap 500023 01 Put the filler cap back on an...

Page 35: ...e The level cannot be compensated and no fuel can flow out of the fuel tank Fuel tap open The knurled screws are turned counterclockwise as far as possible The level can be compensated and the fuel ca...

Page 36: ...at lock 700131 01 The seat lock is located to the right of the seat You can lock it with the ignition key 5 29 Owner s manual 500031 10 You can find the owner s manual in its protective case on the un...

Page 37: ...e storage compartment under the seat 5 31 Passenger footrests 700135 01 The passenger footrests can be folded up and down Possible states Passenger footrests folded up For operation without a passenge...

Page 38: ...5 32 Shift lever 700137 01 The shift lever is mounted on the left side of the engine 700138 01 The gear positions can be seen in the photograph The neutral or idle position is between the first and s...

Page 39: ...ide stand 700139 01 The side stand is coupled with the safety electric starter system see the riding instruc tions Possible states Side stand folded out The vehicle can be supported on the side stand...

Page 40: ...ront and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling characteristics due to non ap...

Page 41: ...Adjust the basic position of handbrake lever p 71 Adjust the basic position of the footbrake lever Get used to handling the vehicle on a car park before making a longer trip Try also to ride as slowl...

Page 42: ...ing characteristics at high speed Adapt your speed according to your payload Ride more slowly if your motorcycle is loaded with cases or other baggage Maximum speed with baggage 130 km h 80 8 mph Warn...

Page 43: ...h a way that it cannot be burned or singed by the hot exhaust system If you carry any baggage make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dist...

Page 44: ...ll 1 000 km 621 4 mi Check the chain tension p 65 Clean the chain p 64 Check the tire condition p 84 Check the tire air pressure p 85 Check the front brake fluid level p 71 Check the rear brake fluid...

Page 45: ...closed space without an effective exhaust extraction system Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic components and safety equip...

Page 46: ...ction test of the combination instrument is finished When starting DO NOT open the throttle If you open the throttle during the start ing procedure fuel is not injected by the engine management system...

Page 47: ...ck Warning Danger of accidents Malfunctions caused by incorrect ignition key position Do not change the ignition key position during a journey Warning Danger of accidents Distraction from traffic acti...

Page 48: ...s been run in Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational and with a full tank...

Page 49: ...elease the clutch and open the throttle Info You can see the positions of the 6 forward gears in the figure The neutral or idle position is between the first and second gears First gear is used for st...

Page 50: ...lt 7 5 Braking Warning Danger of accidents If you brake too hard the wheels can lock Adapt your braking to the traffic situation and the road conditions Warning Danger of accidents Reduced braking due...

Page 51: ...ar appropriate to your road speed On long downhill stretches use the braking effect of the engine Change down one or two gears but do not overstress the engine In this way you have to brake far less a...

Page 52: ...ll over Brake the motorcycle Shift gear to neutral Switch off the ignition by turning the ignition key to the position Info If the engine is switched off with the emergency OFF switch and the ignition...

Page 53: ...sonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected s...

Page 54: ...l fuel tank capacity approx 13 5 l 3 57 US gal Super unleaded ROZ 95 RON 95 PON 91 p 165 Close the filler cap p 32 100121 10 Press the SET button for two seconds The fuel level warning lamp switches o...

Page 55: ...ect fit ting and leaks x Clean check and grease the O ring of the fuel hose connection x Check the cable harness of the throttle valve body for damage and cor rect positioning x Attachments Check the...

Page 56: ...75 Change brake fluid x Check brake lines for damage and leakage Check the free play of the foot brake lever p 74 Check braking Check screws and guide bolts of brake system for tightness x Chassis Ch...

Page 57: ...5 000 km 3 107 mi after every race K100A every 10 000 km 6 214 mi J1A annually J2A every 2 years 8 2 Important maintenance work to be carried out by an authorized KTM workshop as additional order K100...

Page 58: ...andlebar to the straight ahead position Align the work stand to the front with the adapters to the fork legs Work stand front 61029055300 Info Always jack up the rear of the motorcycle first Jack up t...

Page 59: ...d screw it into the link forks Work stand adapter 61029055110 Work stand rear 61029055100 Stand the motorcycle upright align the work stand to the rear and jack up the motorcy cle 9 4 Taking the rear...

Page 60: ...e understood as a guideline and should always be the basis of your own personal chassis adaptation Do not change the adjustments at random or by more than 40 since otherwise the riding characteristics...

Page 61: ...s Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping 9 7 Adjusting the rebound damping of the fork Info The hydraulic rebound damping det...

Page 62: ...ssion damping in low and high speed range separately Dual Compression Control The term low speed and high speed refer to the movement of the shock absorber during compression and not the riding speed...

Page 63: ...ing to the shock absorber type Guideline Compression damping low speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Info Turn clockwise to increase damping turn counterc...

Page 64: ...to the shock absorber type Guideline Compression damping high speed Comfort 2 5 turns Standard 2 0 turns Sport 1 5 turns Full payload 1 5 turns Info Turn clockwise to increase damping turn counterclo...

Page 65: ...nd damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping 9 12 Bleeding the fork...

Page 66: ...Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Environmental hazard Problem materia...

Page 67: ...of the secondary power train chain engine sprocket rear sprocket bearings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or...

Page 68: ...ust the chain tension p 66 9 16 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power...

Page 69: ...ve to the reference marks The rear wheel is then correctly aligned Info The upper chain section must be taut Chain wear is not always even so you should check this setting at different chain positions...

Page 70: ...ar sprocket engine sprocket are worn Replace rear sprocket engine sprocket Info The engine sprocket rear sprocket and chain should always be replaced together For safety reasons the chain has no chain...

Page 71: ...this measurement at differ ent chain positions Maximum distance at the longest sec tion of the chain 272 mm 10 71 in If distance is greater than the specified measurement Have the chain changed Info...

Page 72: ...ear brake discs in several places to ensure that it conforms to measurement Info Wear reduces the thickness of the brake disc in the area of the brake disc Brake discs wear limit Front 3 6 mm 0 142 in...

Page 73: ...while riding 9 21 Checking the front brake fluid level Warning Danger of accidents Brake system failure If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system...

Page 74: ...mark this indicates a leakage in the brake system or worn out brake linings Have the brake system checked in an authorized KTM workshop and do not ride any further Warning Skin irritations Brake fluid...

Page 75: ...tacks paint Use only clean brake fluid from a sealed container Move the brake fluid reservoir mounted on the handlebar to a horizontal position 100181 10 Loosen screw Remove cover with membrane Add br...

Page 76: ...ess Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the front brake linings x Check the brake linings for damage and cracking If there is wear or tearing Change t...

Page 77: ...vel corrected in an authorized KTM workshop Reconnect spring 9 25 Checking rear brake fluid level Warning Danger of accidents Brake system failure If the brake fluid level falls below the MIN mark thi...

Page 78: ...eakage in the brake system or worn out brake linings Have the brake system checked in an authorized KTM workshop and do not ride any further Warning Skin irritations Brake fluid can cause skin irritat...

Page 79: ...e fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 100176 10 Stand the vehicle upright Remove the screw cap with t...

Page 80: ...nimum thickness is less than specified Change the rear brake linings x Check the brake linings for damage and cracking If there is wear or tearing Change the rear brake linings x 9 28 Removing front w...

Page 81: ...out of the fork 9 29 Installing the front wheel x Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them...

Page 82: ...c Fully tighten screws Guideline Screw front brake caliper M10x1 25 45 Nm 33 2 lbf ft Loctite 243 600826 10 Take the front from the work stand p 56 Pull the front wheel brake and push down hard on the...

Page 83: ...swing the brake caliper support to the side Warning Danger of accidents Reduced braking due to damaged brake discs Always lay the wheel down in such a way that the brake disc is not damaged Take the...

Page 84: ...and swingarm Install the rubber damper and rear sprocket carrier in the rear wheel Stand the rear wheel in the swingarm and mount the brake caliper on the brake disc 100147 10 Push the brake caliper...

Page 85: ...e engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers They eventually wear out during operation If the rubber dampers are not changed in time the rear sprocket ca...

Page 86: ...rear wheel x p 81 9 33 Checking the tire condition Warning Danger of accidents Uncontrollable handling behavior caused by a flat tire For your own safety have damaged tires changed immediately Warnin...

Page 87: ...havior of the motorcycle Worn tires have a negative effect on riding behavior especially on wet surfaces 400602 10 Check the front and rear tires for cuts run in objects and other damage If the tires...

Page 88: ...2 0 bar 29 psi Tire air pressure with passenger fully loaded Front 2 0 bar 29 psi Rear 2 2 bar 32 psi If the tire pressure does not meet specifications Correct tire pressure Mount dust cap 9 35 Remov...

Page 89: ...must be inserted into the frame Push the locking pin into the lock housing and push the back of the seat down until the locking pin locks in place with an audible click Remove the ignition key from th...

Page 90: ...l tank and move it backwards Place the fuel tank on the vehicle so that the left spoiler is still lying on the compensat ing tank see illustration Place a cloth between the compensating tank and the s...

Page 91: ...battery x Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact wi...

Page 92: ...700162 10 Disconnect the negative minus cable of the battery Detach rubber band 700163 10 Fold up positive terminal cover Disconnect the positive plus cable of the battery Detach rubber band 700164 10...

Page 93: ...operate the motorcycle with a discharged battery or without a battery In both cases electrical components and safety devices can be damaged The vehi cle is therefore no longer roadworthy 9 40 Installi...

Page 94: ...ver Connect plug in connector 700163 11 Secure the cover with rubber band Connect positive cable Position positive terminal cover 700162 11 Secure the cover with rubber band Attach the minus cable Pos...

Page 95: ...ycling operator Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info...

Page 96: ...use the battery charger to test rest potential and start potential of the bat tery and to test the generator With this device you cannot overcharge the battery Info Never remove lid Charge the battery...

Page 97: ...ect fuses Use only fuses with the prescribed amperage Never by pass or repair fuses Info The main fuse protects all power consumers in the vehicle It is located in the starter relay housing next to th...

Page 98: ...sert the new main fuse Fuse 58011109130 p 153 Info If the new fuse burns out contact an authorized KTM workshop Replace protective cover Position the fuel tank p 88 Mount the seat p 87 Set the clock p...

Page 99: ...ottle valve control unit Fuse 4 10A fuel pump Fuse 5 10A radiator fan Fuse 6 10A horn brake light flasher light alarm system optional Fuse 7 15A high beam low beam parking light tail light license pla...

Page 100: ...e with a spare fuse of the right rating Fuse 75011088010 p 153 Fuse 75011088015 p 153 Info If the new fuse burns out contact an authorized KTM workshop Tip Put a new spare fuse in the fuse box for fut...

Page 101: ...on the Map Select switch on the outside of the frame Pull the Map Select switch out of the holder 700198 01 Turn the adjusting wheel until the desired digit is next to marking Info Position 0 has no f...

Page 102: ...ct responsiveness Set the Map Select switch to Standard Set the adjusting wheel to position 3 4 5 6 7 8 or 9 Standard homologated performance with balanced responsiveness 700196 11 Position the Map Se...

Page 103: ...ENANCE WORK ON CHASSIS AND ENGINE 101 700170 10 Swing the headlight mask forward 700171 01 Disconnect plug in connector 700172 10 Remove the screw fitting on both sides Place the headlight mask to one...

Page 104: ...ENGINE 102 9 46 Installing the headlight mask with the headlight 700172 11 Position the headlight mask Mount and tighten screws on both sides Guideline Screw headlight mask M6 5 Nm 3 7 lbf ft 700171 0...

Page 105: ...adlight mask M6 5 Nm 3 7 lbf ft Check the lighting function 9 47 Changing the low beam bulb Note Damage to reflector Keep the glass of the bulb free of grease Clean the glass bulb with a clean cloth b...

Page 106: ...MAINTENANCE WORK ON CHASSIS AND ENGINE 104 700169 10 Remove screws 700170 10 Fold the headlight mask forward...

Page 107: ...nterclockwise and remove it Detach the connector Position the new headlight bulb in the headlight housing Connect the connector Low beam high beam HB3 P20d p 153 Info Insert the headlight bulb so that...

Page 108: ...ft Check lighting function 9 48 Change the high beam bulb Note Damage to reflector Keep the glass of the bulb free of grease Clean the glass bulb with a clean cloth before mounting Any grease on the...

Page 109: ...orward 600829 10 Turn headlight lamp counterclockwise and remove it Detach the connector Position the new headlight bulb in the headlight housing Connect the connector Low beam high beam HB3 P20d p 15...

Page 110: ...adlight mask M6 5 Nm 3 7 lbf ft Check lighting function 9 49 Changing the parking light bulb Note Damage to reflector Keep the glass of the bulb free of grease Clean the glass bulb with a clean cloth...

Page 111: ...and remove it 700176 01 Pull the parking light bulb out of the holder Insert a new parking light bulb in the holder Parking light W2 1x9 5d p 153 Position the bulb holder and turn it clockwise as far...

Page 112: ...ocket and turn it clockwise until it stops Flasher light BAU15s p 153 Position the diffuser Insert the screw and turn it counterclockwise first until it engages in the thread Tighten the screw slightl...

Page 113: ...a light colored wall behind a horizontal area make a mark as high as the center of the high beam headlight Make another mark at a distance of under the first mark Guideline Distance 5 cm 2 in Stand th...

Page 114: ...forward 700177 01 Adjust the beam distance of the headlight by turning screw Guideline For a motorcycle with rider the light dark boundary must be exactly on the lower mark the mark is created in Chec...

Page 115: ...sk M6 5 Nm 3 7 lbf ft Check the low beam headlight adjustment p 110 If the boundary between light and dark does not meet specifications Adjust the light range of the low beam headlight p 112 9 54 Adju...

Page 116: ...n clockwise to increase the beam width turn counterclockwise to reduce the beam width If you have a heavy payload you will need to correct the headlight range 700169 10 Fold the headlight mask up Posi...

Page 117: ...e permissible without danger of function prob lems 125 C 257 F 100167 10 The coolant is cooled by the air stream and a radiator fan which is controlled by a ther moswitch The lower the speed the less...

Page 118: ...t of the reach of children Remove the seat p 86 Reinstall the fuel tank p 87 700181 10 Condition Engine is cold Stand the motorcycle upright on a horizontal surface Remove the cap of the compensating...

Page 119: ...oolant level in the radiator The radiator must be completely filled If the coolant level does not meet specifications Rectify the coolant level and find out the cause of the loss Alternative 1 Coolant...

Page 120: ...and skin eyes and clothing If fuel gets into your eyes rinse immediately with water and con tact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doc...

Page 121: ...se p 162 If you had to add more coolant than the specified amount 0 50 l 0 53 qt Fill bleed the cooling system x p 120 Mount the radiator cap Position the fuel tank p 88 Mount the seat p 87 9 58 Drain...

Page 122: ...cycle upright Place a suitable container under the engine Remove screw Remove the radiator cap Completely drain the coolant Mount screw with a new seal ring and tighten it Guideline Plug drain hole of...

Page 123: ...es without bubbles at the vent hole and then mount and tighten the bleeder screw immediately Alternative 1 Coolant p 162 Alternative 2 Coolant mixed ready to use p 162 Fill the radiator completely wit...

Page 124: ...ol down When the engine is cool check the coolant level in the radiator and if necessary add coolant Remove the cap of the compensating tank and add coolant until the coolant level is up to the MAX ma...

Page 125: ...with increasing wear of the clutch lining disc Do not use brake fluid Move the clutch fluid reservoir mounted on the handlebar to a horizontal position 100194 10 Check the fluid level The fuel level...

Page 126: ...ions Adjust the play in the gas Bowden cable x p 125 Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine always make sure ther...

Page 127: ...n gas Bowden cable 3 5 mm 0 12 0 2 in Tighten counter nut 9 64 Checking engine oil level Info The engine oil level must be checked when the engine is at operating temperature Stand the motorcycle upri...

Page 128: ...Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under cold water immediat...

Page 129: ...n the oil drain plug with a magnet Mount the oil drain plug with the magnet and seal ring and tighten it Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft 9 67 Removing the oil filter x W...

Page 130: ...lations Place a suitable container under the engine 700188 01 Remove screws Remove the oil filter cover with the O ring Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000...

Page 131: ...unt oil filter covers and Mount and tighten the screws Guideline Screw oil filter cover M5 6 Nm 4 4 lbf ft 9 69 Cleaning the oil screens x Warning Danger of scalding Engine oil and gear oil get very h...

Page 132: ...l grease filters fuel cleaning substances brake fluid batteries etc according to regulations Place a suitable container under the engine 700191 01 Remove plug with oil screen and the O rings 700192 01...

Page 133: ...ring Guideline Plug oil screen M20x1 5 15 Nm 11 1 lbf ft 700194 01 Position oil screen with the O rings Mount and tighten plug with the O ring Guideline Plug oil screen M20x1 5 15 Nm 11 1 lbf ft 9 70...

Page 134: ...it Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or ru...

Page 135: ...ferent types of engine oil If appropriate change the engine oil Install and tighten the oil filler plug with O ring Danger Danger of poisoning Exhaust gases are poisonous and can result in unconscious...

Page 136: ...is in gear Shift gear to neutral The vehicle is in gear and the side stand is folded out Shift gear to neutral Defect in safety start system Have the safety start system checked Engine turns although...

Page 137: ...fan system Have the radiator fan system checked Air in cooling system Fill bleed the cooling system x p 120 FI warning lamp MIL lights flashes Defect in fuel injection system Read the error memory wit...

Page 138: ...not switched off when vehicle was parked Recharge the battery x p 93 Battery is not charged by generator Check charging voltage Combination instrument shows nothing in the display Fuse 1 blown Change...

Page 139: ...IL 08 FI warning lamp MIL flashes briefly 8x Possible cause Input signal from throttle grip sensor too low Input signal from throttle grip sensor too high Flashing code FI of warning lamp MIL 09 FI wa...

Page 140: ...g code FI of warning lamp MIL 15 FI warning lamp MIL flashes 1x long 5x short Possible cause Input signal from rollover sensor too low Input signal from rollover sensor too high Flashing code FI of wa...

Page 141: ...MIL flashes 3x long 3x short Possible cause Malfunction in injection valve circuit cylinder 1 Flashing code FI of warning lamp MIL 37 FI warning lamp MIL flashes 3x long 7x short Possible cause Malfu...

Page 142: ...warning lamp MIL 60 FI warning lamp MIL flashes 6x long Possible cause Malfunction in throttle stepper motor circuit Flashing code FI of warning lamp MIL 68 FI warning lamp MIL flashes 6x long 8x sho...

Page 143: ...FLASHING CODE 141 Flashing code FI of warning lamp MIL 92 FI warning lamp MIL flashes 9x long 2x short Possible cause Malfunction in voltage supply circuit of EPT control unit internal...

Page 144: ...gulations Info If you clean the motorcycle regularly its value and appearance are maintained over a long period Avoid direct sunshine on the motorcycle during cleaning Before you clean the motocycle s...

Page 145: ...covers on the handlebar instruments to allow water to evaporate After the motorcycle has cooled off oil or grease all moving parts and bearings Clean the chain p 64 Treat bare metal parts except for b...

Page 146: ...n it with cold water Warm water would reinforce the effect of the salt Clean the motorcycle p 142 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with a wax bas...

Page 147: ...ty as possible so that you can fill up with fresh fuel when you put the motorcycle back into operation Clean the motorcycle p 142 Change the engine oil and filter clean the oil screens x p 126 Check t...

Page 148: ...y Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 14 2 Putting into operation after storage Take the front fr...

Page 149: ...0 13 mm 0 0028 0 0051 in Crankshaft bearing 2 roller bearings Conrod bearing Needle bearing Piston pin bearing Bronze bush Pistons Forged light alloy Piston rings 1 L ring 1 tapered compression pisto...

Page 150: ...8AI 9 Spark plug electrode gap 0 9 mm 0 035 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid Electric starter automatic decompressor 15 1 Capacity engine oil Engin...

Page 151: ...il filter cover M5 6 Nm 4 4 lbf ft Screw oil pump cover M5 6 Nm 4 4 lbf ft Loctite 243 Plug vacuum connection M6 10 Nm 7 4 lbf ft Loctite 243 Screw Autodecompression M6 3 4 Nm 2 2 3 lbf ft Loctite 243...

Page 152: ...rail M6 10 Nm 7 4 lbf ft Loctite 243 Screw timing chain tensioning rail M6 10 Nm 7 4 lbf ft Loctite 243 Screw valve cover M6 10 Nm 7 4 lbf ft Screw water pump cover M6 10 Nm 7 4 lbf ft Screw water pu...

Page 153: ...net M12x1 5 20 Nm 14 8 lbf ft Oil pressure regulator valve plug M12x1 5 20 Nm 14 8 lbf ft Plug oil bore M14x1 5 15 Nm 11 1 lbf ft Loctite 243 Engine case stud M16x1 5 25 Nm 18 4 lbf ft Loctite 243 Rot...

Page 154: ...Front Disc brake with radially screwed four piston brake caliper floating brake disc Rear Disc brake with single piston brake caliper floating Brake discs diameter Front 320 mm 12 6 in Rear 240 mm 9 4...

Page 155: ...150 kg 331 lb Maximum permissible rear axle load 200 kg 441 lb Maximum permissible overall weight 350 kg 772 lb Battery YTZ10S Battery voltage 12 V Nominal capacity 8 6 Ah maintenance free Fuse 58011...

Page 156: ...Dunlop Sportmax GPR Alpha 10 160 60 R 17 M C 69H TL Dunlop Sportmax GPR Alpha 10 Additional information is available in the Service section under http www ktm com 17 2 Capacity fuel Total fuel tank c...

Page 157: ...cks Full payload 10 clicks Rebound damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Spring length with preload spacer s 352 mm 13 86 in Spring rate Weight of rider 7...

Page 158: ...rt 1 5 turns Full payload 1 5 turns Compression damping low speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport...

Page 159: ...AL DATA SHOCK ABSORBER 157 Gas pressure 10 bar 145 psi Static sag 25 mm 0 98 in Riding sag 60 65 mm 2 36 2 56 in Fitted length 376 mm 14 8 in Shock absorber fluid Shock absorber oil SAE 2 5 50180342S1...

Page 160: ...ft Screw pressure regulator M5 4 Nm 3 lbf ft Screw seat lock M5 3 Nm 2 2 lbf ft Loctite 222 Screw side cover M5 2 Nm 1 5 lbf ft Screw starter cable on starter M5 3 Nm 2 2 lbf ft Lower radiator bracket...

Page 161: ...egulator rectifier M6 8 Nm 5 9 lbf ft Nut manifold on cylinder head M8 25 Nm 18 4 lbf ft Copper paste Nut rear sprocket screw M8 35 Nm 25 8 lbf ft Loctite 243 Remaining nuts chassis M8 30 Nm 22 1 lbf...

Page 162: ...ite 243 Remaining nuts chassis M10 50 Nm 36 9 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw bottom shock absorber M10 45 Nm 33 2 lbf ft Loctite 243 Screw foot brake pedal M10 25 Nm 18 4...

Page 163: ...HTENING TORQUES 161 Screw steering head M20x1 5 12 Nm 8 9 lbf ft Adjusting ring of swingarm bearing M24x1 5 25 Nm 18 4 lbf ft Screw front wheel spindle M24x1 5 40 Nm 29 5 lbf ft Nut rear wheel spindle...

Page 164: ...torex products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant in countries with high temperatures also Use of low quality ant...

Page 165: ...e corresponding properties KTM recommends Motorex products Synthetic engine oil Supplier Motorex Motorex KTM Cross Power 4T Engine oil SAE 10W 50 According to JASO T903 MA p 168 SAE p 168 SAE 10W 50 G...

Page 166: ...c fluid 15 According to ISO VG 15 Guideline Use only hydraulic fluid that complies with the specified standards see specifications on the container and that possesses the corre sponding properties KTM...

Page 167: ...SUBSTANCES 165 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91...

Page 168: ...and polishing materials for metal rubber and plastic Specification KTM recommends Motorex products Supplier Motorex Protect Shine 645 Contact spray Specification KTM recommends Motorex products Suppli...

Page 169: ...2000 Motorcycle cleaner Specification KTM recommends Motorex products Supplier Motorex Moto Clean 900 Onroad chain spray Specification KTM recommends Motorex products Supplier Motorex Chain Lube 622...

Page 170: ...e intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with...

Page 171: ...hain checking for dirt 64 checking for wear 69 cleaning 64 Chain tension adjusting 66 checking 65 Chassis number 16 Cleaning 142 143 Clutch fluid level checking rectifying 123 Clutch lever 19 basic po...

Page 172: ...32 changing 126 draining 126 refilling 131 Engine oil level checking 125 Environment 9 F Filler cap closing 32 opening 32 Filling up fuel 51 Flasher bulb changing 109 Flasher switch 21 Flashing code 1...

Page 173: ...02 removing 100 High beam bulb changing 106 Horn button 21 I Ignition lock 22 Indicator lights 25 K Key number 16 L Light switch 20 Loading the vehicle 40 Low beam bulb changing 103 M Main fuse changi...

Page 174: ...ding 45 starting up 45 S Seat mounting 87 removing 86 Seat lock 34 Service schedule 53 55 Shift lever 36 Shifting 45 Shock absorber 58 compression damping general 60 compression damping high speed adj...

Page 175: ...INDEX 173 Tire condition checking 84 Tool set 35 Transport 8 Troubleshooting 134 136 Type label 16 U Use definition 7 V View of vehicle front left 12 right rear 14 W Warranty 7 Work rules 8...

Page 176: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 10 2008 Photo Mitterbauer 3211370en 3211370en...

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