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KTM 690 ENDURO AUS/UK 2008, Owner'S Manual

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KTM 690 ENDURO AUS/UK 2008 Owner'S Manual Download Page 58

MAINTENANCE WORK ON CHASSIS AND ENGINE

56

9MAINTENANCE WORK ON CHASSIS AND ENGINE

9.1

Jacking up the motorcycle

Note

Danger of damage

 

Danger of damage by the vehicle running away or falling over.

–

Always place the vehicle on a firm and even surface.

100241-01

–

Jack up the motorcycle on the underride guard underneath the engine. The wheels must
no longer touch the ground.

–

Secure the motorcycle against falling over.

9.2

Removing the motorcycle from the work stand

Note

Danger of damage

 

Danger of damage by the vehicle running away or falling over.

–

Always place the vehicle on a firm and even surface.

–

Remove the motorcycle from the work stand and rest it on its side stand.

–

Remove the work stand.

Summary of Contents for 690 ENDURO AUS/UK 2008

Page 1: ...OWNER S MANUAL 2008 690 ENDURO EU 690 ENDURO AUS UK ART NO 3211239en...

Page 2: ......

Page 3: ...it is never possible to exclude small deviations arising from further development in design and construction All specifications are not binding KTM Sportmotorcycle AG in particular reserves the right...

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

Page 5: ...er 26 Combination instrument control lamps 26 Combination instrument Display 27 Combination instrument speed display 28 Setting kilometers or miles 28 Combination instrument time 29 Setting the clock...

Page 6: ...ng play of steering head bearing x 66 Adjusting the handlebar angle x 67 Handlebar position 67 Adjusting handlebar position x 68 Checking chain dirt 69 Cleaning the chain 69 Checking the chain tension...

Page 7: ...cting fluid level of hydraulic clutch 129 Checking play in gas Bowden cable 130 Adjusting play in gas Bowden cable x 131 Removing the engine guard 132 Installing the engine guard 132 Checking engine o...

Page 8: ...CONTENTS 6 STANDARDS 171 INDEX 172...

Page 9: ...technical 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 s...

Page 10: ...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 greasin...

Page 11: ...xhaust system get very hot when the engine is running Do not place the vehicle where there are flammable or explosive substances Switch off the engine and remove the ignition key Use straps or other s...

Page 12: ...hat will probably lead to severe and permanent injury or death Caution Danger that could possibly lead to slight injuries Note Danger of serious damage to machine or material Warning Risk of environme...

Page 13: ...IMPORTANT NOTES 11 The owner s manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold...

Page 14: ...VIEW OF VEHICLE 12 3 VIEW OF VEHICLE 3 1 View of vehicle front left side 100234 10...

Page 15: ...VIEW OF VEHICLE 13 1 Hand brake lever 2 Clutch lever 3 Handrail 4 Filler cap 5 Seat 6 Front brake caliper 7 Shift lever 8 Engine number 9 Side stand 10 Footrest 11 Seat release strap...

Page 16: ...VIEW OF VEHICLE 14 3 2 View of vehicle rear right side 100235 10...

Page 17: ...Light switch flasher switch horn 4 Combination instrument 5 Emergency OFF switch electric starter button 6 Throttle grip 7 Chassis number 8 Rear brake caliper 9 Passenger footrest 10 Shock absorber re...

Page 18: ...BERS 16 4 LOCATION OF SERIAL NUMBERS 4 1 Chassis number 100217 10 The chassis number is stamped on the steering head on the right 4 2 Type label 100218 10 Type label is located on the upper right fram...

Page 19: ...10 The key number can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place 4 4 Engine number 100211 10 The engine number is stamped on th...

Page 20: ...IAL NUMBERS 18 4 5 Fork part number 100214 10 The fork part number is stamped on the inner side of the fork stub 4 6 Shock absorber part number 100216 10 Shock absorber part number can be viewed from...

Page 21: ...9 10 The clutch lever is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 5 2 Hand brake lever 100220 10 The hand break lever is fitted on the right sid...

Page 22: ...High beam on Light switch is turned upwards In this position the high beam and the tail light are switched on 5 4 Light switch 100222 10 The light switch is fitted on the left side of the handlebar P...

Page 23: ...ctuated 5 6 Flasher switch 500021 10 The flasher switch is fitted on the left side of the handlebar Possible states Flasher light off Flasher light left on Flasher switch pressed to the right The flas...

Page 24: ...ically to 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...

Page 25: ...operated in this position 5 10 Emergency OFF switch 100225 10 The emergency OFF switch is fitted on the left side of the handlebar Possible states Emergency OFF switch off In this position the ignitio...

Page 26: ...nition steering lock 100221 10 The ignition steering lock is located in front of the seat Possible states Ignition off In this position the ignition circuit is interrupted a running engine stops and a...

Page 27: ...nction areas Function buttons Tachometer Indicator lights Display 5 14 Combination instrument function buttons 700117 01 Press the MODE button to change the display mode Possible display modes are tot...

Page 28: ...otorcycle Possible states Flashing indicator flashes green in flash rhythm Flasher light is switched on Idling speed indicator lamp lights up green Transmission is in neutral High beam indicator lamp...

Page 29: ...you switch on the ignition all display segments light up for a second as a function test 400404 01 LEnGTth Following the display function test the wheel circumference LEnGth is shown for one sec ond...

Page 30: ...01 The speed is displayed in kilometers per hour km h or miles per hour Mph 5 19 Setting kilometers or miles Info If you change the unit the ODO value is retained and converted accordingly Making the...

Page 31: ...the MODE button pressed until the display mode changes from Km h to Mph or from Mph to Km h Specification Activation duration of MODE button 10 s 5 20 Combination instrument time 700115 01 The time is...

Page 32: ...MODE button and the SET button pressed simultaneously The time is set 5 22 Combination instrument ODO display 700120 01 In ODO mode the total distance covered is shown in kilometers or miles Info This...

Page 33: ...nt setting resetting TRIP 2 display Info The tripmaster TRIP 2 operates constantly and counts up to 999 9 You can use the tripmaster to measure trips or the distance between refuelling stops After rea...

Page 34: ...l warning light begins to light up 5 26 Combination instrument coolant temperature indicator 700124 01 The temperature indicator in the display consists of 12 bars The more bars that light up the hott...

Page 35: ...nd insert 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 28 Closing filler cap 100228 01 Put the filler cap back...

Page 36: ...Handrails 100229 10 The handrails are used for moving the motorcycle around When you have a passenger the passenger can hold on the handrails during the journey 5 30 Seat release 100230 10 The seat c...

Page 37: ...ger footrests can be folded up and down Possible states Passenger footrests folded up For operation without a passenger Passenger footrests folded down For operation with a passenger 5 32 Shift lever...

Page 38: ...sitions can be seen in the photograph The neutral or idle position is between the first and second gears 5 33 Foot brake pedal 100232 10 The footbrake pedal is located in front of the right footrest T...

Page 39: ...ectric starter system see the riding instruc tions Possible states Side stand folded out The vehicle can be supported on the side stand The safety electric starter system is active Side stand folded i...

Page 40: ...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 accidents Uncontrollable handling behavio...

Page 41: ...of clutch lever P 129 Adjust the free travel of the handbrake lever P 77 Adjust the basic position of the foot brake pedal x P 85 Get used to handling the vehicle on a car park before making a longer...

Page 42: ...and with a full tank driver and passenger with protective clothing and helmet baggage Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and or tank ru...

Page 43: ...nstable 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 th...

Page 44: ...tion all 1 000 km 621 4 mi Check the chain tension P 70 Clean the chain P 69 Check the tire condition P 98 Checking the tire air pressure P 100 Check the front brake brake fluid level P 78 Check the r...

Page 45: ...or run the engine in a closed space Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic components and safety equipment may be damaged Neve...

Page 46: ...ntil the combination instrument func tion test is finished Do not open the throttle when starting If you open the throttle when starting the engine management injects no fuel and the engine cannot sta...

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: ...ear release the clutch and open the throttle Info For the positions of the 6 forward gears see the illustration The neutral or idle position is between the first and second gears First gear is used fo...

Page 50: ...op immediately If you shift to neutral the FI warning lamp MIL begins to flash Info From the flash rhythm you can deduce a two digit number the so called flash code The flash code tells you which comp...

Page 51: ...t the brake discs must first be cleaned by brak ing To brake release the throttle and operate the front and rear brakes simultaneously On sandy wet or slippery surfaces use the rear brake Braking shou...

Page 52: ...n of components by excessive load The side stand is designed for the weight of the motorcycle only Do not sit on the motorcycle when it is supported by the side stand only The side stand and or the fr...

Page 53: ...d can escape if the tank is overfilled See specifications on filling up with fuel Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothin...

Page 54: ...Fuel tank content 12 l 3 2 US gal Super unleaded ROZ 95 RON 95 PON 91 P 168 Close the filler cap P 33 100240 10 Press the SET function button for 2 seconds The fuel level warning lamp switches off TR...

Page 55: ...for damage correct 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 Attach...

Page 56: ...id x Check brake lines for damage and leakage Check the free play of the foot brake lever P 85 Check braking Check screws and guide bolts of brake system for tightness x Chassis Check shock absorber a...

Page 57: ...every 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 ord...

Page 58: ...ace 100241 01 Jack up the motorcycle on the underride guard underneath the engine The wheels must no longer touch the ground Secure the motorcycle against falling over 9 2 Removing the motorcycle from...

Page 59: ...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 could deter...

Page 60: ...yload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping Mount protection covers 9 5 Adjusting rebound damping of fork Info The hydraulic rebound damp...

Page 61: ...gh speed range separately Dual Compression Control The term low and high speed refers to the movement of the shock absorber during compression and not the riding speed of the motorcycle The low and hi...

Page 62: ...ping low speed 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 8 Adjusting high...

Page 63: ...clockwise with an open ended spanner until it stops Info Do not loosen nut Turn back counterclockwise the number of turns corresponding to the shock absorber type Specification Compression damping hig...

Page 64: ...rber or carry out any mainte nance on it yourself 100247 10 Turn the adjusting screw clockwise until it stops Turn back counterclockwise the number of clicks corresponding to the shock absorber type S...

Page 65: ...ork legs downwards Info The dust boots should remove dust and coarse dirt particles from the fork tubes Over time dirt can penetrate behind the dust boots If this dirt is not removed the oil seals beh...

Page 66: ...ards Remove the screws on the right fork leg Push the fork protection downwards 9 13 Positioning the fork protection 100292 11 Position the fork protection on the left fork leg Mount and tighten screw...

Page 67: ...the motorcycle P 56 100298 10 Move the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel No play should be noticeable in the steering head bearing If th...

Page 68: ...ion Screw top steering head M20x1 5 10 Nm 7 4 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid strains Fully tighten screw Specification Screw top triple clamp M8 17 Nm 12...

Page 69: ...andlebar support and the handlebar clamp must be the same at the front and rear Fully tighten screw Specification Screw handlebar clamp M8 20 Nm 14 8 lbf ft Loctite 243 9 17 Handlebar position 400271...

Page 70: ...cables and lines Remove the two screws Remove the handlebar support Place the handlebar support in the required position Fit and tighten the two screws Specification Screw handlebar support M10 40 Nm...

Page 71: ...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 72: ...s 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 73: ...not meet specifications Adjust the chain tension P 71 9 22 Adjusting chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components...

Page 74: ...e position relative 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 repeat this measurement at dif...

Page 75: ...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 76: ...not always even so you should repeat this measurement at differ ent chain positions Maximum distance at the longest chain section 272 mm 10 71 in If the distance is greater than the specified measurem...

Page 77: ...ghten screws and Specification Remaining screws chassis M6 10 Nm 7 4 lbf ft Conditions Number of teeth 45 teeth Insert nut in hole Position the chain guide Mount and tighten screws and Specification R...

Page 78: ...Wear limit of brake discs front 4 5 mm 0 177 in Rear 3 5 mm 0 138 in If the brake disc thickness is less than the specified value Change the brake disc 9 27 Checking free play of hand brake lever Warn...

Page 79: ...100252 10 Adjust the free travel of the handbrake lever with the adjustment screw Info Turn the adjustment screw clockwise to reduce free travel The pressure point moves away from the handlebar Turn t...

Page 80: ...rear brake fluid replaced according to the service plan in an authorized KTM workshop 100253 10 The brake fluid level must not fall below the center of the level viewer when the brake fluid reservoir...

Page 81: ...cording to the service plan in an authorized KTM workshop Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid b...

Page 82: ...by KTM were tested over long periods and ensure optimal braking properties The type names of brake pads are entered in the homologation documents Info Brake linings available from accessory suppliers...

Page 83: ...s 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 100255 10 Check the brake linings for minimum...

Page 84: ...linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construction and friction factor of the brake linings and therefore the brake power can differ...

Page 85: ...s back the brake pistons Ensure that brake fluid does not overflow from the brake fluid reservoir and suction it off if necessary Info Make sure when pushing back the brake pistons that you do not pre...

Page 86: ...rt the bolt and mount the split pin Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot 100254 12 Adjust the brake fluid level to level Spec...

Page 87: ...ston and check free travel Specification Free play at foot brake lever 3 5 mm 0 12 0 2 in Info You will know that contact has been made with the foot brake cylinder piston when there is increased resi...

Page 88: ...cylinder so that the foot brake pedal has the necessary free travel Hold screws in place and tighten the nuts Specification Nut foot brake cylinder screw M6 10 Nm 7 4 lbf ft Check the free play of th...

Page 89: ...of the rear brake x P 87 9 37 Topping up brake fluid of rear brake x Warning Danger of accidents Brake system failure MINIf the brake fluid level falls below the MIN mark this indicates a leakage in...

Page 90: ...gulations Info Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and p...

Page 91: ...ings 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 100260 10 Check the brake linings for minim...

Page 92: ...linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construction and friction factor of the brake linings and therefore the brake power can differ...

Page 93: ...ir and suc tion it off if necessary Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes 100288 10 Remove split pin remove bolt toward the left...

Page 94: ...ie on the brake disc and there is a tight spot Adjust the brake fluid level to the MAX mark Brake fluid DOT 4 DOT 5 1 P 166 Refit screw with membrane Info Clean up overflowed or spilt brake fluid imme...

Page 95: ...00263 10 Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork Info Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down in such...

Page 96: ...grease shaft seal rings and bearing surface of the spacing sleeves Long life grease P 170 Fit the spacing sleeves 100266 10 Lift the front wheel into the fork position it and insert the wheel spindle...

Page 97: ...the brake piston Remove nut Remove chain adjuster Holding the rear wheel withdraw the wheel spindle 100268 01 Push the rear wheel forwards as far as possible and take the chain off the rear sprocket...

Page 98: ...ear wheel always operate the footbrake until the pressure point is reached Checking the rear hub rubber dampers x P 97 100269 10 Check parts for damage and wear Replace damaged or worn parts Remove th...

Page 99: ...d right adjusters in similar positions Tighten nut Specification Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Operate the foot brake lever repeatedly until the brake linings lie on the brake disc...

Page 100: ...rt the wheel spindle in the hub To check the play hold the rear wheel tight and try to rotate the rear sprocket Info Measure the play on the outside of the rear sprocket Play in rubber dampers rear wh...

Page 101: ...of accidents Reduced road grip with new tires New tires have a smooth roll surface and therefore cannot provide full road grip The entire roll surface must be roughened in the first 200 kilometers 124...

Page 102: ...m tread depth Minimum tread depth 2 mm 0 08 in If the minimum tread depth is insufficient Change the tires 9 46 Checking tire air pressure Info Low tire air pressure leads to abnormal wear and overhea...

Page 103: ...f the tire pressure does not meet specifications Correct tire pressure Mount dust cap 9 47 Checking spoke tension Warning Danger of accidents Unstable riding behavior due to loose spokes If you ride w...

Page 104: ...a high note Spoke nipple front wheel M5 4 Nm 3 lbf ft Spoke nipple rear wheel M5 4 Nm 3 lbf ft Info If you hear different tone frequencies from different spokes this is an indication of different spok...

Page 105: ...orrectly mounted 9 50 Removing the battery x Warning Risk of injury Battery acid and battery gases cause serious cauterization Keep batteries out of the reach of children Wear suitable protective clot...

Page 106: ...the battery rack Info Never operate the motorcycle with a discharged battery or without a battery In both cases electrical components can safety equipment can be damaged The vehicle is then no longer...

Page 107: ...in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Warning Environm...

Page 108: ...oltage and the charge time are exceeded electrolyte escapes through the breathing holes The battery capacity is then reduced If the battery becomes discharged from starting it must be recharged immedi...

Page 109: ...Never remove the lid Charge the battery according to the instructions on the battery casing After charging switch off and disconnect the battery charger Specification The charge current charge voltag...

Page 110: ...mponents and switch off the engine Remove the seat P 102 600604 10 Remove protection covers 600605 10 Remove a defective main fuse with a needle nose plier Check parts for damage and wear Replace dama...

Page 111: ...03 Set the clock P 29 9 54 Changing fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat Switch off all power consuming co...

Page 112: ...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 plate lamp Fuse 8 10A for supplementary equipment access...

Page 113: ...orrect rating only Fuse 75011088010 P 158 Fuse 75011088015 P 158 Info If the new fuse burns out contact an authorized KTM workshop Tip Replace the spare fuse in the fuse box so that it will be availab...

Page 114: ...nced Set the adjusting wheel to position 2 Advanced homologated performance with extremely direct responsiveness Set the Map Select switch to Standard Set the adjusting wheel to position 3 4 5 6 7 8 o...

Page 115: ...nsuming components and switch off the engine 600607 10 Protect the fender against damage by covering it with a cloth Remove the screws on the left and right Tilt the headlight mask forward and lift it...

Page 116: ...the headlight mask with the headlight 100294 11 Connect the connectors of headlight and flasher lights Check lighting function 100295 10 Remove the cloth from the fender attach the headlight mask to...

Page 117: ...9 58 Changing the headlight 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 glass will evaporate by th...

Page 118: ...ing bar Replace the rubber cap Attach the connector Refit the headlight mask with the headlight P 114 9 59 Changing the parking light bulb Note Damage to reflector Keep the glass of the bulb free of g...

Page 119: ...reflector Keep the glass of the bulb free of grease Clean the glass bulb with a clean cloth before mounting Any grease on the glass will evaporate by the heat and be deposited on the reflector 100301...

Page 120: ...amp setting 400408 10 On a light colored wall with a horizontal area in front of it make a mark as high as the center of the low beam headlight Make another mark at a distance of under the first mark...

Page 121: ...ndary between light and dark must be exactly on the lower mark for a motor cycle with a rider mark is applied under Checking headlight adjustment Info Turn clockwise to increase the light range turn c...

Page 122: ...into the engine and result in increased wear Remove air filter 9 64 Installing the air filter x 100287 10 Check parts for damage and wear Change damaged or worn parts Change the air filter if it is di...

Page 123: ...the engine forces the coolant to flow The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap Heat expansion causes excess coolant to flow into the co...

Page 124: ...adiator radiator hoses or other cooling system components when the engine is hot Allow the engine and cool ing system to cool down If you scald yourself hold the affected area under cold water immedia...

Page 125: ...49 F If the antifreeze of the cooling liquid does not meet specifications Correct antifreeze of coolant Check the coolant level in the compensating tank The coolant level must be within the range show...

Page 126: ...meet specifications Correct the coolant level and find out the cause of the loss Alternative 1 Coolant P 166 Alternative 2 Coolant mixed ready to use P 166 Refit the radiator cap 9 67 Checking the co...

Page 127: ...is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolants out of the reach of children 100283 10 Condition Engine is cold Stand the motorcycle o...

Page 128: ...is under high pressure Do not open the radiator radiator hoses or other cooling system components when the engine is hot Allow the engine and cool ing system to cool down If you scald yourself hold t...

Page 129: ...ling the cooling system x Warning Danger of poisoning Coolants are poisonous and a health hazard Avoid contact between coolants and skin eyes and clothing If fuel gets into your eyes rinse immediately...

Page 130: ...he compensating tank 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...

Page 131: ...the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 100282 10 Adjust the basic setting of the cl...

Page 132: ...fluid 15 P 167 Check parts for damage and wear Replace damaged or worn parts Position the cover with the membrane Mount and tighten screws 9 72 Checking play in gas Bowden cable 400192 10 Move the han...

Page 133: ...art the engine and let it run idle Move the handlebar to and fro over the entire steer ing range The idle speed must not change If the idle speed changes Adjust the play in the gas Bowden cable x P 13...

Page 134: ...ntal surface 100198 10 Remove screws on the left and right Pull the engine guard forward out of the holders and set it down 9 75 Installing the engine guard 100199 10 Slide the engine guard into holde...

Page 135: ...e Check the engine oil level Info After switching off the engine wait for one minute and then check The engine oil must be between the lower and upper edge of the oil level viewer If the engine oil le...

Page 136: ...ted area under cold water immediately Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc accordi...

Page 137: ...20 Nm 14 8 lbf ft 9 79 Removing the oil filter x Warning 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...

Page 138: ...the oil filter insert out of the oil filter casing Circlip pliers reverse 51012011000 100203 10 Remove screws Remove oil filter cover with O ring Pull the oil filter insert out of the oil filter casin...

Page 139: ...cover M5 6 Nm 4 4 lbf ft 9 81 Cleaning oil screens x Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and gloves If you s...

Page 140: ...ove the plug with the oil screen and O rings Drain the remaining engine oil Thoroughly clean parts and sealing area Check parts for damage and wear Replace damaged or worn parts 100207 10 Position oil...

Page 141: ...0209 10 Remove filler plug with O ring from the clutch cover and add engine oil Engine oil 1 70 l 1 8 qt Engine oil SAE 10W 60 P 167 Refit plug with O ring and tighten it Danger Danger of poisoning Ex...

Page 142: ...the clutch cover and add engine oil Engine oil SAE 10W 60 P 167 Refit plug with O ring and tighten it Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and or de...

Page 143: ...he vehicle 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 turn...

Page 144: ...stat defective Have thermostat checked Fuse 5 blown Change the fuses of individual power consumers P 109 Defect in radiator fan system Have the radiator fan system checked Air in cooling system Fill t...

Page 145: ...d Fuse 2 blown Change the fuses of individual power consumers P 109 Set the clock P 29 Battery discharged Ignition not switched off when vehicle was parked Recharge the battery x P 105 Battery is not...

Page 146: ...lant x 13 FI warning lamp MIL flashes 1x long 3x short Input signal from intake air temperature sensor too low high Check the intake air temper ature sensor x 14 FI warning lamp MIL flashes 1x long 4x...

Page 147: ...circuit Check the lambda probe heating x 54 FI warning lamp MIL flashes 5x long 4x short Fault short circuit in secondary air valve circuit Check the secondary air valve x 55 FI warning lamp MIL flas...

Page 148: ...lamp MIL flashes 9x long 1x short Malfunction in CAN bus com munication Check CAN bus communica tion x 92 FI warning lamp MIL flashes 9x long 2x short Malfunction in voltage supply circuit of throttl...

Page 149: ...regulations 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...

Page 150: ...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 69 Treat bare metal parts except for b...

Page 151: ...on salted roads clean it with cold water Warm water would reinforce the effect of the salt Clean the motorcycle P 147 Treat the engine the swingarm and all other bare or galvanized parts except brake...

Page 152: ...Make sure the tank is as empty as possible so that you can fill up with fresh fuel when you put the motorcycle back into operation Clean the motorcycle P 147 Change engine oil and oil filter clean oi...

Page 153: ...ime only 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 Remove the...

Page 154: ...ve play cold 0 07 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...

Page 155: ...enerator 12 V 224 W Spark plug NGK LKAR 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 deco...

Page 156: ...648 Screw oil filter cover M5 6 Nm 4 4 lbf ft Screw oil pump cover M5 6 Nm 4 4 lbf ft Loctite 243 Oil jet piston cooling M6x0 75 4 Nm 3 lbf ft Loctite 243 Screw locking lever M6 10 Nm 7 4 lbf ft Locti...

Page 157: ...243 Screw valve cover M6 10 Nm 7 4 lbf ft Screw water pump cover M6 10 Nm 7 4 lbf ft Screw water pump wheel M6 10 Nm 7 4 lbf ft Loctite 243 Screw cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw cylind...

Page 158: ...agnet 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 I...

Page 159: ...Disc brake with dual piston brake caliper floating Rear Disc brake with single piston brake caliper floating Diameter of brake discs front 300 mm 11 81 in Rear 240 mm 9 45 in Wear limit of brake disc...

Page 160: ...Maximum permissible front axle load 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...

Page 161: ...tire Rear tire 90 90 21 54 H TL Metzeler Enduro 3 Sahara 140 80 18 70 H TL Metzeler Enduro 3 Sahara For further information see the Service section under http www ktm com 17 2 Capacity fuel Fuel tank...

Page 162: ...icks Sport 10 clicks full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks Spring length with preload spacer s 472 mm 18 58 in Spring rate...

Page 163: ...1 turn full payload 1 turn Compression damping low speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clic...

Page 164: ...TECHNICAL DATA SHOCK ABSORBER 162 Fitted length 395 mm 15 55 in...

Page 165: ...sk M5 5 Nm 3 7 lbf ft Screw side stand switch M5 3 Nm 2 2 lbf ft Screw seat lock M5 3 Nm 2 2 lbf ft Loctite 222 Screw starter cable on starter M5 3 Nm 2 2 lbf ft Nut foot brake cylinder screw M6 10 Nm...

Page 166: ...Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw main silencer holder M8 25 Nm 18 4 lbf ft Screw main silencer holder on fuel tank M8 25 Nm 18 4 lbf ft Loctite 243 Screw rear footrest...

Page 167: ...2 lbf ft Loctite 243 Screw foot brake pedal M10LH 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar support M10 40 Nm 29 5 lbf ft Screw engine bearer on frame M10 45 Nm 33 2 lbf ft Screw side stand M10 35...

Page 168: ...trol and Motorex products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Specification Use only suitable coolant even in countries with high temperatures Using i...

Page 169: ...the corresponding properties KTM recommends Motorex products Synthetic engine oil Supplier Motorex Cross Power 4T Fork oil SAE 5 according to SAE P 171 SAE 5 Specification Use only oils that comply wi...

Page 170: ...es with the specified standards see specifications on the container and that possesses the corre sponding properties KTM recommends Motorex products Supplier Motorex Hydraulic Fluid 75 Super unleaded...

Page 171: ...11 Cleaning and polishing materials for metal rubber and plastic Specification KTM recommends Motorex products Supplier Motorex Protect Shine 645 Contact spray Specification KTM recommends Motorex pro...

Page 172: ...Therm 2000 Motorcycle cleaner Specification KTM recommends Motorex products Supplier Motorex Moto Clean 900 Offroad chain spray Specification KTM recommends Motorex products Supplier Motorex Chain Lu...

Page 173: ...ong service 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 lubri...

Page 174: ...anging the front brake linings 81 of front brake checking 81 of rear brake checking 89 Brakes 48 Braking 48 C Chain checking dirt 69 checking wear 74 cleaning 69 Chain guide adjusting 75 Chain tension...

Page 175: ...OFF switch 23 Engine running in 40 Engine characteristic adjusting 111 Engine guard installing 132 removing 132 Engine number 17 Engine oil changing 133 draining 134 refilling 139 topping up 140 Engi...

Page 176: ...sition 67 adjusting 68 Handrails 34 Headlight Adjusting the light range 119 Headlight bulb changing 115 Headlight flasher switch 21 Headlight mask with headlight fitting 114 removing 113 Horn 22 23 I...

Page 177: ...rocket checking for wear 73 Rear wheel fitting 96 removing 95 Riding 45 Starting up 45 S Seat mounting 103 removing 102 Seat release 34 Shift lever 35 Shifting 45 Shock absorber 57 adjusting rebound d...

Page 178: ...ues 163 165 Engine 152 153 Engine tightening torques 154 156 Fork 160 Shock absorber 161 162 Tire air pressure checking 100 Tire condition checking 98 Transport 9 Troubleshooting 141 143 Type label 16...

Page 179: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 03 2008 Photo Mitterbauer 3211239en 3211239en...

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