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KTM 690 Duke USA, Owner'S Manual

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KTM 690 Duke USA Owner'S Manual Download Page 81

11

SERVICE WORK ON THE CHASSIS

79

11.11

Checking the chain, rear sprocket and engine sprocket

100132-10

–

Check the rear sprocket and engine sprocket for wear.
» If the rear sprocket and engine sprocket are worn:

–

Change the power set.

x

Info

The engine sprocket, rear sprocket and chain should always be replaced
together.

Summary of Contents for 690 Duke USA

Page 1: ...OWNER S MANUAL 2013 690 Duke USA Art no 3213005en...

Page 2: ......

Page 3: ...fications are non binding KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications prices colors forms materials services designs equipment etc without prior...

Page 4: ...ccording to the international quality management standard ISO 9001 KTM uses quality assurance processes that lead to the maximum possible quality of the products Issued by T V Management Service KTM S...

Page 5: ...ice 19 4 VIEW OF VEHICLE 20 4 1 View of vehicle front left side 20 4 2 View of vehicle rear right side 22 5 SERIAL NUMBERS 24 5 1 Chassis number type label 24 5 2 Key number 25 5 3 Engine number 26 5...

Page 6: ...CHASSIS 66 10 1 Compression damping of the shock absorber 66 10 2 Adjusting the spring preload of the shock absorber x 66 10 3 Adjusting the footrests 67 11 SERVICE WORK ON THE CHASSIS 70 11 1 Raising...

Page 7: ...14 7 Removing the headlight mask with the headlight 116 14 8 Refitting the headlight mask with the headlight 117 14 9 Changing the headlight bulb 118 14 10 Changing the parking light bulb 120 14 11 C...

Page 8: ...g torques 156 22 3 Capacities 159 22 3 1 Engine oil 159 22 3 2 Coolant 160 22 3 3 Fuel 160 22 4 Chassis 160 22 5 Electrical system 162 22 6 Tires 162 22 7 Fork 162 22 8 Shock absorber 163 22 9 Chassis...

Page 9: ...standing In the interest of your own safety have these jobs performed by an authorized KTM workshop There your motorcycle will be optimally cared for by specially trained experts using the specialist...

Page 10: ...he homologated version 2 2 Safety advice A number of safety instructions need to be followed to operate the vehicle safely Therefore read this manual carefully The safety instruc tions are highlighted...

Page 11: ...easures are not taken Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken Note Identifies a danger that will lead to considerable ma...

Page 12: ...2 SAFETY ADVICE 10 2 4 Overview of labels B01405 10...

Page 13: ...ype label Canada 2 Information chain tension 3 Information emission control 4 Information putting into operation 5 Information noise emission 6 Type label USA B01399 01 Type label Canada 700207 01 Inf...

Page 14: ...2 SAFETY ADVICE 12 B01401 01 Information emission control 700210 01 Information putting into operation...

Page 15: ...ould immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying KTM North America Inc If NHTSA receives multiple similar complaints it may open an investigati...

Page 16: ...er Support 1119 Milan Ave Amherst OH 44001 USA Phone 440 985 3553 www ktmusa com KTM Canada Inc Customer Support 1375 1 Marie Victorin Saint Bruno QC J3V 6B7 Phone 450 441 4451 x 4250 www ktmcanada co...

Page 17: ...moval or puncturing of the main silencer baffles header pipes or any other components which conduct exhaust gases 2 Removal or puncturing of parts of the intake system 3 Lack of proper maintenance 4 R...

Page 18: ...sk Wear protective clothing helmet boots gloves pants and jacket with protectors every time you ride the vehicle Always wear protective clothing that is in good condition and meets the legal requireme...

Page 19: ...l of an end of life motorcycle Your authorized KTM dealer will be glad to advise you 2 14 Owner s Manual It is important that you read this Owner s Manual carefully and completely before making your f...

Page 20: ...auxiliary substances such as fuel and lubricants as specified in the Owner s Manual 3 3 Spare parts accessories For your own safety only use spare parts and accessory products that are approved and or...

Page 21: ...serve these exactly you will ensure a much longer service life for your motorcycle 3 5 Figures The figures contained in the manual may depict special equipment In the interest of clarity some componen...

Page 22: ...4 VIEW OF VEHICLE 20 4 1 View of vehicle front left side B01406 10...

Page 23: ...4 VIEW OF VEHICLE 21 1 Clutch lever p 28 2 Seat 3 Passenger seat 4 Handrails p 44 5 Seat lock p 43 6 Engine number p 26 7 Shift lever p 45 8 Side stand p 46...

Page 24: ...4 VIEW OF VEHICLE 22 4 2 View of vehicle rear right side B01407 10...

Page 25: ...ch p 30 2 Turn signal switch p 31 2 Horn button p 29 3 Filler cap 4 Ignition steering lock p 32 5 Emergency OFF switch p 31 5 Electric starter button p 32 6 Hand brake lever p 28 7 Chassis number type...

Page 26: ...5 SERIAL NUMBERS 24 5 1 Chassis number type label B01409 10 The chassis number 1 is stamped on the right side of the steering head The type label USA 2 is located on the frame tube on the right...

Page 27: ...0 The type label Canada 3 is located on the frame tube on the left 5 2 Key number B00755 10 The key number 1 can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the...

Page 28: ...6 5 3 Engine number C00302 10 The engine number 1 is located on the left side of the engine under the engine sprocket 5 4 Fork part number C00303 10 The fork part number 1 is stamped on the inner side...

Page 29: ...5 SERIAL NUMBERS 27 5 5 Shock absorber part number C00304 10 The shock absorber part number 1 is on the left side of the shock absorber...

Page 30: ...r 1 is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 6 2 Hand brake lever 602570 10 The hand brake lever 1 is fitted on the right side of the handleb...

Page 31: ...ttle grip 1 is fitted on the right side of the handlebar 6 4 Horn button C00308 11 The horn button 1 is fitted on the left side of the handlebar Possible states Horn button in neutral position Horn bu...

Page 32: ...l 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 6 6 Headlight flasher switch C00307 11 The headlight flasher switc...

Page 33: ...ressed to the right The turn signal switch automatically returns to the central position after use To switch off the turn signal press the turn signal switch towards the switch housing 6 8 Emergency O...

Page 34: ...ing lock B00925 01 The ignition steering lock 1 is located in front of the upper triple clamp Possible states Ignition off In this position the ignition circuit is interrupted a running engine stops a...

Page 35: ...s p 33 2 Tachometer p 34 3 Indicator lamps p 34 4 Display p 35 6 11 2 function buttons 401426 10 You can change the display mode with the MODE button 1 Possible display modes are the odometer ODO trip...

Page 36: ...the motorcy cle Possible states The turn signal indicator light flashes green simultaneously with the turn signal The turn signal is switched on The idling speed indicator lamp lights up green The tr...

Page 37: ...as detected an emission or safety critical error The battery warning lamp lights up red The voltage in the vehicle system is too low ABS warning lamp lights up flashes yellow Status or error messages...

Page 38: ...of the 17 front wheel with a series pro duction tire The display then changes to the last selected mode 6 11 6 Speed display 401443 10 The speed 1 is shown in kilometers per hour km h or in miles per...

Page 39: ...on repeatedly until the ODO mode is active Keep the MODE button pressed until the display mode changes from km h to mph or from mph to km h 6 11 8 Time 401443 11 The time is shown in area 1 of the dis...

Page 40: ...n and the SET button pressed simultaneously The time is set 6 11 10 ODO display 401444 01 In the ODO display mode the total distance traveled is shown in kilometers or miles Info This value is retaine...

Page 41: ...IP 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 999...

Page 42: ...mark the display automatically changes to TRIP F and starts to count from 0 0 regardless of the previous display mode Info The low fuel warning lamp lights up in parallel to the TRIP F display 6 11 1...

Page 43: ...always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if...

Page 44: ...ed igni tion keys must be replaced Turn the ignition key 90 clockwise Open the filler cap 6 13 Closing the filler cap B00927 01 Fold down the filler cap Turn the ignition key 90 clockwise Press down t...

Page 45: ...ROLS 43 6 14 Seat lock B00928 10 The seat lock 1 is located on the left side of the vehicle It can be locked with the ignition key 6 15 Tool set B00929 10 The tool set 1 is located under the passenger...

Page 46: ...have a passenger the passenger can hold on the handrails during the journey 6 17 Passenger footrests B00931 01 The passenger footrests can be folded up and down Possible states Passenger footrests fo...

Page 47: ...45 6 18 Shift lever 602555 11 The shift lever 1 is mounted on the left side of the engine 602555 10 The gear positions can be seen in the figure The neutral or idle position is between the first and s...

Page 48: ...hicle The side stand is used for parking the motorcycle Info The side stand must be folded up during motorcycle use The side stand is coupled with the safety starting system see the riding instruc tio...

Page 49: ...crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control...

Page 50: ...and the service record at vehicle handover Before your first trip read the entire operating instructions carefully Get to know the controls Adjust the basic position of the clutch lever p 81 Adjust t...

Page 51: ...lmet baggage Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and or tank rucksack Mount and secure suitcase and tank rucksack according to the manuf...

Page 52: ...ble handling characteristics due to slipped baggage Check the way your baggage is fixed regularly Warning Danger of burns A hot exhaust system can burn baggage Fasten your baggage in such a way that i...

Page 53: ...vel p 90 Check the front brake linings p 88 Check the rear brake linings p 93 Check the brake system function Check the coolant level in the compensating tank p 127 Check the chain for dirt p 73 Check...

Page 54: ...engines have a negative effect on the service life of the engine Always warm up the engine at low engine speeds B00782 10 Turn the emergency OFF switch to the position Switch on the ignition by turni...

Page 55: ...quipped with a safety starting system You can only start the engine if the transmission is in neutral or if the clutch lever is pulled when a gear is engaged If the side stand is folded out and you sh...

Page 56: ...lock up 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 traffi...

Page 57: ...e tires have been run in Warning Danger of accidents Unstable handling characteristics Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational a...

Page 58: ...ar release 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 fo...

Page 59: ...the brakes Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a dirty or wet brake system by riding and braking gently Warning Danger of accidents R...

Page 60: ...ve Warning Danger of accidents Locking of the wheels due to braking action of the engine Pull the clutch during emergency braking full brake application and when braking on a slippery surface When bra...

Page 61: ...t components such as exhaust system radiator engine shock absorber and the brake system Allow these components to cool down before starting work on them Note Danger of damage The parked vehicle may ro...

Page 62: ...nd forward with your foot as far as it will go and lean the vehicle on it Lock the steering by turning the handlebar fully to the left pressing down the ignition key to the position and turning it to...

Page 63: ...the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If con...

Page 64: ...e engine Open the filler cap p 41 Fill the fuel tank with fuel up to the lower edge A of the filler neck Total fuel tank capacity approx 13 8 l 3 65 US gal Super unleaded ROZ 95 RON 95 PON 91 p 170 Cl...

Page 65: ...heck the rear brake linings p 93 Check the brake discs p 84 Check the brake lines for damage and leakage Check the rear brake fluid level p 90 Check the free travel of the foot brake lever p 88 Check...

Page 66: ...Change the air filter Clean the air filter box x Check the fuel pressure x Check the CO adjustment with the KTM diagnostics tool x Check rectify the fluid level of the hydraulic clutch p 82 Check the...

Page 67: ...9 SERVICE SCHEDULE 65 Periodic interval...

Page 68: ...can be adjusted separately although the transition between high speed and low speed is gradual Thus changes in the high speed range affect the compression damping in the low speed range and vice vers...

Page 69: ...ustment unit 1 Guideline Spring preload Standard 4 clicks Hook wrench T106S Info The spring preload can be set to 10 different positions 10 3 Adjusting the footrests C00329 10 Remove lock ring 1 Remov...

Page 70: ...HE CHASSIS 68 C00330 10 Remove screws 2 C00331 01 Adjust the footrest bracket to the desired position C00330 10 Mount and tighten screws 2 Guideline Screw front footrest bracket M8 25 Nm 18 4 lbf ft L...

Page 71: ...10 TUNING THE CHASSIS 69 C00332 01 Mount the rider footrest with the spring and pin C00329 10 Mount lock ring 1 Repeat the operations on the opposite side...

Page 72: ...1 Mount the support of the wheel stand Insert the adapter in the rear wheel stand Adapter 61029055120 Rear wheel stand 61029055400 Stand the motorcycle upright align the lifting gear with the swingarm...

Page 73: ...d Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Preparatory work Raise the motorcycle with the rear wheel stand p 70 602543 01...

Page 74: ...away or fall over Always place the vehicle on a firm and even surface Secure the motorcycle against falling over Remove the front wheel stand 11 5 Removing the passenger seat B00928 10 Insert the ign...

Page 75: ...er seat until it clicks into place Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly After mounting the passenger seat check that it is lo...

Page 76: ...nd grease and clean them with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be dispo...

Page 77: ...procket rear sprocket bearings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to...

Page 78: ...ain upwards near the vertical rib of the swingarm and measure the chain tension A Info The upper chain section B must be taut Chain wear is not always even Repeat this measurement at different chain p...

Page 79: ...bearings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme case...

Page 80: ...e markings on the left and right chain adjusters 4 are in the same position relative to the reference marks C The rear wheel is then correctly aligned Info The upper chain section must be taut Chain w...

Page 81: ...in rear sprocket and engine sprocket 100132 10 Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the power set x Info The engine sprocket re...

Page 82: ...n section Info Chain wear is not always even Repeat this measurement at different chain posi tions Maximum distance B at the longest chain section 272 mm 10 71 in If the distance B is greater than the...

Page 83: ...6 10 Nm 7 4 lbf ft Loctite 243 11 12 Adjusting the basic position of the clutch lever Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar Turn t...

Page 84: ...d B00944 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 Check the fluid level Fluid level below container rim 4 mm...

Page 85: ...ave been approved and or recommended by KTM Service work and repairs must be performed properly Your authorized KTM workshop will be glad to help The ABS is a safety system that prevents locking of th...

Page 86: ...r wheel spins This causes the ABS to switch off To reenable the ABS the vehicle must be stopped and the ignition switched off The ABS is reenabled when the vehicle is switched on again The ABS warning...

Page 87: ...or deformation are visible on the brake disc Replace the brake disc 12 4 Checking the brake fluid level of the front brake Warning Danger of accidents Brake system failure If the brake fluid level dr...

Page 88: ...ke linings are completely worn down Check the brake system and do not continue riding Your autho rized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation o...

Page 89: ...rake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Preparatory work Check the front brake linings p 88 B00948 10 Main work Move the brake fluid r...

Page 90: ...e brake discs are destroyed Check the brake linings regularly 602583 10 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified...

Page 91: ...rake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to over heating Adjust the free travel on foot brake lev...

Page 92: ...bf ft Loctite 243 Attach spring 1 12 9 Checking rear brake fluid level Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicates a leakag...

Page 93: ...system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep...

Page 94: ...ines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Preparatory work Check the...

Page 95: ...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 Check the brak...

Page 96: ...rake disc Pull the brake caliper carefully back from the brake disc and hang it to one side Info Do not pull the hand brake lever while the brake caliper is removed 602546 10 Loosen screws 5 and 6 Uns...

Page 97: ...e wheel bearing for damage and wear If the wheel bearing is damaged or worn Replace the wheel bearing x Clean grease and mount the left and right spacers and the shaft seal rings Long life grease p 17...

Page 98: ...are in contact with the brake disc and there is a pressure point Fix the hand brake lever in the activated posi tion The brake calipers straighten Tighten screws 6 Guideline Screw front brake caliper...

Page 99: ...torcycle with the rear wheel stand p 70 602563 10 Main work Remove screw 1 and pull wheel speed sensor 2 out of the hole Remove nut 3 Remove chain adjuster 4 602564 10 Pull out wheel spindle 5 to the...

Page 100: ...Take the rear wheel carefully out of the swingarm without damaging the rim and or brake disc Info Do not operate the foot brake when the rear wheel is removed 13 4 Installing the rear wheel x Warning...

Page 101: ...eplace the wheel bearing x Remove bushing 1 Clean and grease the mating surfaces of the bushings and the shaft seal rings Long life grease p 172 Install the bushing Clean and grease the thread of the...

Page 102: ...he adjust ing screws and tighten the nut Guideline In order for the rear wheel to be correctly aligned the markings on the left and right chain adjusters must be in the same position relative to the r...

Page 103: ...rear wheel x p 97 602568 10 Main work Check bearing 1 If the bearing is damaged or worn Replace the bearings x Check rubber dampers 2 of the rear hub for damage and wear If the rubber dampers of the...

Page 104: ...fferent tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accid...

Page 105: ...Info Note local national regulations concerning the minimum tread depth Minimum tread depth 2 mm 0 08 in If the tread depth is less than the minimum permissible depth Change the tires Check the age of...

Page 106: ...omfort and maximum tire service life 400695 01 Remove the protection cap Check the tire pressure when the tires are cold Tire air pressure solo Front 2 0 bar 29 psi Rear 2 0 bar 29 psi Tire air pressu...

Page 107: ...tery acid and battery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets i...

Page 108: ...up and out of the battery holder 14 2 Installing the battery x B00963 11 Main work Position the battery in the battery holder Info The terminals of the battery must face in the direction of travel At...

Page 109: ...tact with battery acid and battery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms In the event of skin contact rinse with large amounts of water If batter...

Page 110: ...he charging current charging voltage and charging time are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle...

Page 111: ...d start potential of the battery and to test the alternator With this device you cannot overcharge the battery Info Never remove lid 1 Switch off the charger after charging Disconnect the battery Guid...

Page 112: ...used Use only fuses with the prescribed amperage Never by pass or repair fuses Info The main fuse protects all power consumers of the vehicle The main fuse is under the passenger seat Preparatory work...

Page 113: ...ed out fuse wire A A reserve fuse 3 is located in the starter relay Install a new main fuse Fuse 58011109130 p 161 Tip Insert a new replacement fuse into the starter relay to have it available when ne...

Page 114: ...ed under the passenger seat These fuses protect the return pump and the hydraulic unit of the ABS The third fuse which protects the ABS control unit is located in the fuse box Preparatory work Switch...

Page 115: ...Mount the protection cover Finishing work Mount the passenger seat p 73 14 6 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is l...

Page 116: ...it Fuse 3 10 A fuel pump Fuse 4 10 A radiator fan Fuse 5 10 A horn brake light turn signal alarm system optional Fuse 6 15 A high beam low beam parking light tail light license plate lamp Fuse 7 10 A...

Page 117: ...or repair fuses Use spare fuses with the correct rating only Fuse 75011088010 p 161 Fuse 75011088015 p 161 Tip Replace the spare fuse in the fuse box so that it is available if needed Check that the p...

Page 118: ...g the headlight mask with the headlight Preparatory work Switch off all power consumers and switch off the engine B00972 10 Main work Remove screws 1 602578 11 Fold the headlight mask forward Disconne...

Page 119: ...10 Main work Plug in connector 1 B00972 11 Position the headlight mask Mount and tighten screws 2 Guideline Screw headlight EJOT 2 Nm 1 5 lbf ft Remaining screws chassis M5 5 Nm 3 7 lbf ft Check that...

Page 120: ...p will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off all power consumers and switch off the engine R...

Page 121: ...headlight housing Headlight H4 socket P43t p 162 Info Insert the headlight bulb so that the catches latch into the recesses Attach retaining clamp 3 B00973 10 Mount protection cap 2 Plug in connector...

Page 122: ...f all power consumers and switch off the engine Remove the headlight mask with the headlight p 116 B00975 10 Main work Pull cable sleeve 1 and the socket of parking light 2 carefully out of the housin...

Page 123: ...l glass 1 Press the bulb carefully into the socket turn it counterclockwise by about 30 and pull it out of the socket Info Do not touch the reflector with your fingers and keep it free from grease Pre...

Page 124: ...e A in front of the wall and switch on the low beam Guideline Distance A 5 m 16 ft The rider with luggage and passenger if applicable now mounts the motorcycle Check the headlight setting The light da...

Page 125: ...le with rider and with luggage and a passenger if applicable the light dark boundary must be exactly on the lower mark applied in Checking the headlight setting Info Turn counterclockwise to increase...

Page 126: ...ture without causing any malfunctions 125 C 257 F 100167 10 Cooling takes place by means of the air stream and a radiator fan 4 which is controlled by a thermoswitch The lower the speed the less the c...

Page 127: ...nt out of reach of children Condition The engine is cold Preparatory work Stand the motorcycle upright on a horizontal surface B01001 10 Main work Remove radiator cap 1 and plug 2 from the compensatin...

Page 128: ...ating tank Check the coolant level in the radiator The radiator must be completely filled If the coolant level does not meet specifications Correct the coolant level and find out the cause of the loss...

Page 129: ...ing If contact occurs with the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap and water If coolant is swallowed contact a physici...

Page 130: ...r hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning...

Page 131: ...g bleeding the cooling system x Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes r...

Page 132: ...nt level in the compensating tank p 127 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there i...

Page 133: ...d with marking 2 Set the Map Select switch to Soft Set the adjusting wheel to position 1 Soft Homologated performance with very gentle response Set the Map Select switch to Advanced Set the adjusting...

Page 134: ...ine distance A between the upper edge of your boot and the shift lever Distance between shift lever and upper edge of boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the...

Page 135: ...lever on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle components during the...

Page 136: ...tween the lower and upper edge of the oil level viewer If the engine oil level is not at the specified level Add the engine oil p 139 17 2 Changing the engine oil and filter cleaning the oil screens x...

Page 137: ...ainer under the engine Remove the oil drain plug 1 with the magnet and seal ring Completely drain the engine oil Thoroughly clean the oil drain plug with a magnet B00988 10 Remove screws 2 Remove the...

Page 138: ...ain the engine oil Thoroughly clean the parts and sealing area B00991 10 Insert the oil filter Oil the O rings of the oil filter covers Mount oil filter covers 3 and 6 Mount and tighten the screws Gui...

Page 139: ...aling area B01002 10 Position the oil screen with the O rings Mount and tighten screw plug 8 with the O ring Guideline Plug oil screen M20x1 5 15 Nm 11 1 lbf ft B00994 10 Position the oil screen with...

Page 140: ...ne oil SAE 10W 60 00062010035 p 169 Alternative engine oil Engine oil SAE 10W 50 p 169 Install and tighten the oil filler plug with the O ring Danger Danger of poisoning Exhaust gases are toxic and in...

Page 141: ...performance of the engine oil do not mix different types of engine oil If appropriate change the engine oil Install and tighten the oil filler plug 1 with the O ring Danger Danger of poisoning Exhaus...

Page 142: ...leaners brake fluid etc should be disposed of as stipulated in applicable regulations Info If you clean the motorcycle regularly its value and appearance will be maintained over a long period Avoid di...

Page 143: ...ns in the engine and on the brake system to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 74 Treat bare metal parts except for brake discs and...

Page 144: ...the brake system Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts are cooled down and w...

Page 145: ...ason 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 171 Refuel p 61 Clean the motorcycle p 140 Change the engine oil and filte...

Page 146: ...he engine for a short time only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 19 2 Preparing for use after...

Page 147: ...utral Engine turns but does not start Operating error Carry out the start procedure p 52 Fuse 3 blown Change the fuses of individual power consumers p 113 Coupling of fuel hose connection not connecte...

Page 148: ...lights flashes Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x N The idle indicator lamp does not light up when the transmission is in neutral Gear position...

Page 149: ...ake light and horn are not functional Fuse 5 blown Change the fuses of individual power consumers p 113 Time is not correctly displayed Fuse 1 blown Change the fuses of individual power consumers p 11...

Page 150: ...ning lamp MIL 12 FI warning lamp MIL flashes 1x long 2x short Error level condition Engine coolant temperature sensor input signal too low Engine coolant temperature sensor input signal too high Blink...

Page 151: ...Error level condition Lambda sensor cylinder 1 sensor 1 circuit fault Blink code of FI warning lamp MIL 22 FI warning lamp MIL flashes 2x long 2x short Error level condition Gear position sensor circ...

Page 152: ...cylinder 1 circuit fault Blink code of FI warning lamp MIL 37 FI warning lamp MIL flashes 3x long 7x short Error level condition Ignition coil 1 cylinder 1 circuit fault Blink code of FI warning lamp...

Page 153: ...sor heater cylinder 1 sensor 1 input signal too high Blink code of FI warning lamp MIL 65 FI warning lamp MIL flashes 6x long 5x short Error level condition E PROM error Blink code of FI warning lamp...

Page 154: ...l too low Accelerator position sensor circuit A input signal too high Blink code of FI warning lamp MIL 86 FI warning lamp MIL flashes 8x long 6x short Error level condition Accelerator position senso...

Page 155: ...DBW internal power relay active Blink code of FI warning lamp MIL 92 FI warning lamp MIL flashes 9x long 2x short Error level condition DBW throttle actuator control IC stuck open Blink code of FI wa...

Page 156: ...es 9x long 5x short Error level condition DBW stop function system error stop function B system error Blink code of FI warning lamp MIL 96 FI warning lamp MIL flashes 9x long 6x short Error level cond...

Page 157: ...ld 0 07 0 13 mm 0 0028 0 0051 in Crankshaft bearing 2 roller bearings Conrod bearing Needle bearing Piston pin bearing Piston pin with DLC coating Pistons Forged light alloy Piston rings 1 L ring 1 ta...

Page 158: ...ed 1 550 1 650 rpm Starting aid Electric starter automatic decompressor 22 2 Engine tightening torques Screw membrane fixation M3 2 Nm 1 5 lbf ft Loctite 243 Hose clamp intake flange M4 2 5 Nm 1 84 lb...

Page 159: ...k of camshaft M6 10 Nm 7 4 lbf ft Loctite 243 Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch slave cylinder M6x20 10 Nm 7 4 lbf ft Loctite 243 Screw clutch slave cylinder M6x35 10 Nm 7 4 lbf ft S...

Page 160: ...lbf ft Loctite 243 Screw plug crankshaft clamp M8 20 Nm 14 8 lbf ft Stud exhaust flange M8 10 Nm 7 4 lbf ft Loctite 243 Cylinder head screw M10 Tightening sequence Tighten diagonally beginning with th...

Page 161: ...e 243 Engine case stud M16x1 5 25 Nm 18 4 lbf ft Loctite 243 Rotor nut M18x1 5 100 Nm 73 8 lbf ft Nut engine sprocket M20x1 5 80 Nm 59 lbf ft Loctite 243 Nut inner clutch hub M20x1 5 100 Nm 73 8 lbf f...

Page 162: ...me molybdenum steel tubing powder coated Fork WP Suspension Up Side Down 4357 Shock absorber WP Suspension 4618 with Pro Lever linkage Suspension travel Front 135 mm 5 31 in Rear 135 mm 5 31 in Brake...

Page 163: ...e 1 447 15 mm 56 97 0 59 in Seat height unloaded 835 mm 32 87 in Ground clearance unloaded 175 mm 6 89 in Weight without fuel approx 150 kg 331 lb Maximum permissible front axle load 150 kg 331 lb Max...

Page 164: ...10 W Brake tail light LED License plate lamp LED 22 6 Tires Front tires Rear tires 120 70 ZR 17 M C 58W TL Michelin Pilot Power 160 60 ZR 17 M C 69W TL Michelin Pilot Power Additional information is a...

Page 165: ...JOT 2 Nm 1 5 lbf ft Screw headlight mask EJOT 1 Nm 0 7 lbf ft Screw side stand switch M4 2 Nm 1 5 lbf ft Loctite 243 Remaining screws chassis M5 5 Nm 3 7 lbf ft Retaining clamp brake line M5 3 Nm 2 2...

Page 166: ...octite 243 Screw battery terminal M6 2 Nm 1 5 lbf ft Screw brake fluid reservoir of rear brake M6 5 Nm 3 7 lbf ft Screw chain sliding guard M6 10 Nm 7 4 lbf ft Loctite 243 Screw control unit holder M6...

Page 167: ...sunk screw 25 Nm 18 4 lbf ft Loctite 243 Screw footrest bracket rear M8x45 Countersunk screw 25 Nm 18 4 lbf ft Loctite 243 Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake disc M8 30 Nm 22 1 lbf...

Page 168: ...bf ft Loctite 243 Screw subframe M10 45 Nm 33 2 lbf ft Loctite 243 Banjo bolt brake line M10x1 22 Nm 16 2 lbf ft Banjo bolt pressure modulator M10x1 20 Nm 14 8 lbf ft Screw bottom shock absorber M10x1...

Page 169: ...22 TECHNICAL DATA 167 Screw front wheel spindle M24x1 5 45 Nm 33 2 lbf ft Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Nut steering head M28x1 12 Nm 8 9 lbf ft...

Page 170: ...x products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant also in countries with high temperatures Use of low quality antifre...

Page 171: ...sess the corresponding properties KTM recommends Motorex products Synthetic engine oil Supplier Motorex Cross Power 4T Engine oil SAE 10W 50 According to JASO T903 MA p 174 SAE p 174 SAE 10W 50 Guidel...

Page 172: ...es KTM recommends Motorex products Supplier Motorex Hydraulic Fluid 75 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matc...

Page 173: ...lube for road use Guideline KTM recommends Motorex products Supplier Motorex Chainlube Road Cleaning and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Su...

Page 174: ...grease Guideline KTM recommends Motorex products Supplier Motorex Bike Grease 2000 Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Paint cleaner and polish...

Page 175: ...24 AUXILIARY SUBSTANCES 173 Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Synthetic...

Page 176: ...vice intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated wit...

Page 177: ...ear brake checking 90 Brake linings front brake checking 88 rear brake checking 93 Brake system 83 93 Brakes 57 Brakes applying 57 C Capacity coolant 160 engine oil 138 159 fuel 62 160 Chain checking...

Page 178: ...Customer service 19 E Electric starter button 32 Emergency OFF switch 31 Engine running in 48 Engine characteristics setting 131 Engine number 26 Engine oil adding 139 changing 134 Engine oil level ch...

Page 179: ...ndicator lamps 34 Intended use 8 K Key number 25 L Light switch 30 Loading the vehicle 49 M Main fuse changing 110 Motorcycle cleaning 140 raising with the front wheel stand 71 raising with the rear w...

Page 180: ...position adjusting 132 basic position checking 132 Shifting 54 Shock absorber compression damping general 66 spring preload adjusting 66 Shock absorber part number 27 Side stand 46 Spare parts 18 Star...

Page 181: ...signal bulb changing 121 Turn signal switch 31 Type label 24 U Use definition 8 V View of vehicle left front side 20 rear right side 22 W Warranty 18 Winter operation checks and maintenance steps 142...

Page 182: ...3213005en 3213005en 02 2013 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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