KTM 690 Enduro R 2019 Owner'S Manual Download Page 109

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SERVICE WORK ON THE CHASSIS 11

107

S03338-10

Main work

–

Remove screws

–

Remove the upper part of the air filter box

S03339-10

Note

Engine damage

Unfiltered intake air has a negative effect on

the service life of the engine.
Dust and dirt will enter the engine without an air filter.

–

Never start to use the vehicle without an air filter.

–

Remove air filter

Summary of Contents for 690 Enduro R 2019

Page 1: ...OWNER S MANUAL 2019 690 Enduro R Art no 3213909en ...

Page 2: ......

Page 3: ...rint However minor differences due to further developments in design cannot be ruled out completely All specifications are non binding KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical specifications prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to s...

Page 4: ... ISO 9001 12 100 6061 KTM applies quality assurance processes that lead to the highest possible product quality as defined in the ISO 9001 international quality management standard Issued by TÜV Management Service KTM Sportmotorcycle GmbH Stallhofnerstraße 3 5230 Mattighofen Austria This document is valid for the following models 690 Enduro R EU F9703S8 ...

Page 5: ...es 17 3 3 Spare parts accessories 17 3 4 Service 18 3 5 Figures 18 3 6 Customer service 18 4 VIEW OF VEHICLE 20 4 1 View of vehicle front left example 20 4 2 View of vehicle rear right example 22 5 SERIAL NUMBERS 24 5 1 Vehicle identification number 24 5 2 Type label 24 5 3 Key number 25 5 4 Engine number 25 5 5 Fork part number 26 5 6 Shock absorber article number 26 6 CONTROLS 27 6 1 Clutch leve...

Page 6: ... 6 21 8 Speed time and DST distance 1 49 6 21 9 Speed time and DST2 distance 2 50 6 21 10 AVG average speed ART operating hours and ODO total distance covered 51 7 PREPARING FOR USE 52 7 1 Advice on preparing for first use 52 7 2 Running in the engine 54 7 3 Loading the vehicle 55 8 RIDING INSTRUCTIONS 58 8 1 Checks and maintenance measures when preparing for use 58 8 2 Starting the vehicle 59 8 3...

Page 7: ...ing the fork legs 96 11 7 Checking the steering head bearing play 97 11 8 Adjusting the steering head bearing play 98 11 9 Removing the seat 99 11 10 Mounting the seat 100 11 11 Removing the tool set 100 11 12 Storing the tool set 101 11 13 Take off the side cover 103 11 14 Mounting side cover 104 11 15 Removing the front fender 105 11 16 Installing the front fender 106 11 17 Removing the air filt...

Page 8: ...S TIRES 153 13 1 Removing the front wheel 153 13 2 Installing the front wheel 155 13 3 Removing the rear wheel 157 13 4 Installing the rear wheel 159 13 5 Checking the rear hub damping rubber pieces 163 13 6 Checking the tire condition 165 13 7 Checking tire pressure 167 13 8 Checking the spoke tension 169 13 9 Using tire repair spray 170 14 ELECTRICAL SYSTEM 171 14 1 Removing the 12 V battery 171...

Page 9: ...e basic position of the shift lever 213 16 4 Adjusting the basic position of the shift lever 214 17 SERVICE WORK ON THE ENGINE 215 17 1 Checking the engine oil level 215 17 2 Changing the engine oil and oil filter cleaning the oil screens 216 17 3 Adding engine oil 222 18 CLEANING CARE 224 18 1 Cleaning the motorcycle 224 18 2 Checks and maintenance steps for winter operation 227 19 STORAGE 229 19...

Page 10: ...htening torques 249 22 SUBSTANCES 256 23 AUXILIARY SUBSTANCES 259 24 STANDARDS 261 25 INDEX OF SPECIAL TERMS 262 26 LIST OF ABBREVIATIONS 263 27 LIST OF SYMBOLS 264 27 1 Red symbols 264 27 2 Yellow and orange symbols 264 27 3 Green and blue symbols 265 INDEX 266 ...

Page 11: ...with this symbol requires specialist knowledge and technical understanding In the interest of your own safety have these jobs performed by an authorized KTM workshop Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or...

Page 12: ... rework 1 2 Formats used The typographical formats used in this document are explained below Proprietary name Indicates a proprietary name Name Indicates a protected name Brand Indicates a brand available on the open market Underlined terms Refer to technical details of the vehicle or indicate technical terms which are explained in the glossary ...

Page 13: ...y to advise you 2 2 Misuse The vehicle must only be used as intended Dangers can arise for people property and the environment through use not as intended Any use of the vehicle beyond the intended and defined use constitutes misuse Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respective use 2 3 Safety advice A number of safety...

Page 14: ...invariably lead to fatal or serious permanent injury if the appropriate measures are not taken Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken Note Identifies a danger that will lead to considerable machine and material damage...

Page 15: ... rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below 1 Removal or puncturing of the main silencers 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 Replacing moving parts of the vehicle or parts of the exhaust system or intake syste...

Page 16: ...before you perform any work on the vehicle Only operate the vehicle when it is in perfect technical condition in accordance with its intended use and in a safe and environmentally compatible manner An appropriate driver s license is needed to drive the vehicle on public roads Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop Adhere to the information and warnin...

Page 17: ...hat are to be reused and check them for damage and wear Change damaged or worn parts After completing a repair or service work check the operating safety of the vehicle 2 9 Environment If you use your motorcycle responsibly you can ensure that problems and conflicts do not occur To protect the future of the motorcycle sport make sure that you use your motorcycle legally display environmental consc...

Page 18: ...use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it as needed If you would like to know more about the vehicle or have questions on the material you read please contact an authorized KTM dealer The Owner s Manual is an important component of the vehicle and must be handed over to the new owner if the vehicle is sold The Owner...

Page 19: ...nd in the Service Warranty Booklet 3 2 Fuel auxiliary substances Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system Use fuels and auxiliary substances in accordance with the Owner s Manual and specification 3 3 Spare parts accessories For your own safety only use spare parts and accessory produ...

Page 20: ...r of components such as the drive train brake system or suspension components For this reason it may be necessary to inspect or replace parts before the next scheduled service It is imperative that you adhere to the stipulated run in times and service intervals If you observe these exactly you will ensure a much longer service life for your motorcycle 3 5 Figures The figures contained in the manua...

Page 21: ...IMPORTANT NOTES 3 19 A list of authorized KTM dealers can be found on the KTM website International KTM Website http www ktm com ...

Page 22: ...4 VIEW OF VEHICLE 20 4 1 View of vehicle front left example S03366 10 ...

Page 23: ...ke lever p 27 2 Clutch lever p 27 3 Grab handles p 37 4 Fuel tank filler cap 5 Passenger foot pegs p 38 6 Seat unlocking p 37 7 Compression damping of the shock absorber p 87 8 Side stand p 40 9 Engine number p 25 bk Shift lever p 38 ...

Page 24: ...4 VIEW OF VEHICLE 22 4 2 View of vehicle rear right example S03367 10 ...

Page 25: ...3 Horn button p 28 4 Combination switch p 32 5 Overview of indicator lamps p 35 6 Emergency OFF switch p 30 6 Electric starter button p 31 7 Throttle grip p 28 8 Fork rebound adjustment 9 Vehicle identification number p 24 bk Level viewer engine oil bl Foot brake lever p 39 bm Type label p 24 bn Shock absorber rebound adjustment ...

Page 26: ... 24 5 1 Vehicle identification number 401945 10 The vehicle identification number 1 is stamped on the right side of the steering head 5 2 Type label H01049 10 The type label 1 is located on the right side of the frame ...

Page 27: ...e key number 1 can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place 5 4 Engine number 401949 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket ...

Page 28: ...5 5 Fork part number 401947 10 The fork part number 1 is stamped on the inner side of the fork stub 5 6 Shock absorber article number 402025 10 The shock absorber article number 1 is on the left side of the shock absorber ...

Page 29: ... is fitted on the handlebar on the left The clutch is activated hydraulically and adjusts itself automati cally 6 2 Hand brake lever S03356 10 The hand break lever 1 is fitted on the right side of the handle bar The hand brake lever operates the front brake ...

Page 30: ...ttle grip 1 is fitted on the right side of the handlebar 6 4 Horn button S03358 10 The horn button 1 is fitted on the left side of the handlebar Possible states Horn button in neutral position Horn button pressed The horn is operated in this posi tion ...

Page 31: ...osition the high beam and tail light are switched on 6 6 Turn signal switch S03358 12 The turn signal switch 1 is fitted on the left side of the handle bar Possible states Turn signal off Turn signal light left on Turn signal switch pressed to the left The turn signal switch returns automati cally to the central position after use Turn signal light right on Turn signal switch pressed to the right ...

Page 32: ...03359 10 The emergency OFF switch 1 is fitted on the right side of the handlebar Possible states Emergency OFF switch off In this position the igni tion circuit is interrupted a running engine stops and the engine cannot be started Emergency OFF switch on This position is necessary for operation as the ignition circuit is closed ...

Page 33: ...the handlebar Possible states Electric starter button in basic position Electric starter button is pressed In this position the starter motor is actuated 6 9 ABS button S02157 10 The ABS button 1 is fitted next to the combination instrument on the left Info The ABS button is also used as the ABS warning lamp p 126 ...

Page 34: ...action control are acti vated when LED 1 lights up 1TC ROAD without TC When LEDs 1 and TC light up drive mode ROAD is active and traction control is deactivated 2 OFFROAD Drive mode OFFROAD and traction control are activated when LED 2 lights up 2TC OFFROAD without TC When LEDs 2 and TC light up drive mode OFFROAD is active and traction control is deactivated ...

Page 35: ...n the combination switch The traction control is activated or deactivated using button TC on the combination switch Info Each time the ignition is switched on all three switch LEDs light up for a function check If all three LEDs light up during operation an error has been detected by the engine control unit Contact an authorized KTM workshop immediately ...

Page 36: ...s position the ignition circuit is interrupted a running engine stops and a non running engine will not start The ignition key can be removed Ignition on In this position the ignition 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 ...

Page 37: ...ights up blue The high beam is switched on Fuel level warning lamp lights up orange The fuel level has reached the reserve mark Malfunction indicator lamp lights up orange The OBD has detected an error in the vehicle electronics Come safely to a halt and contact an authorized KTM workshop The coolant temperature warning lamp lights up red The coolant temperature has reached a critical value Stop i...

Page 38: ...s too low Stop immediately taking care not to endanger yourself or other road users in the pro cess and switch off the engine TC indicator lamp lights up flashes yellow If the TC indicator lamp lights up the MTC p 71 is not active If the TC indicator lamp and both drive mode lamps light up at same time an error as been detected Contact an authorized KTM workshop The TC indicator lamp flashes if th...

Page 39: ...t unlocking S03336 10 The loop 1 unlocks the seat 6 14 Grab handles S03277 10 The grab handles 1 are used for moving the motorcycle around If you carry a passenger the passenger can hold onto the grab handles during the trip ...

Page 40: ...oot pegs can be folded up and down Possible states Passenger foot pegs folded up For operation without a pas senger Passenger foot pegs folded down For operation with a pas senger 6 16 Shift lever 401950 10 The shift lever 1 is mounted on the left side of the engine ...

Page 41: ...s can be seen in the photograph The neutral or idle position is between the first and second gears 6 17 Foot brake lever 401956 10 Foot brake lever 1 is located in front of the right footrest The rear brake is engaged with the foot brake lever ...

Page 42: ...tand must be folded up during motorcycle use The side stand is coupled with the safety starting system see the riding instructions Possible states Side stand folded out The vehicle can be supported on the side stand The safety starting system is active Side stand folded in This position is mandatory when riding the motorcycle The safety starting system is inactive ...

Page 43: ... fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in c...

Page 44: ...ronment Do not allow fuel to enter the groundwater the soil or the sewage system S03278 10 Lift cover 1 of fuel tank filler cap and insert the ignition key Turn the ignition key 90 counterclockwise and take off the fuel tank filler cap Info The fuel tank filler cap has a fuel tank breather ...

Page 45: ...79 10 Put the fuel tank filler cap back on and turn the ignition key 90 clockwise Remove the ignition key and fold down the cover 6 21 Combination instrument 6 21 1 Overview S02155 10 1 Overview of indicator lamps p 35 2 Left button 3 Display 4 Right button ...

Page 46: ...ctivated when one of the buttons is pressed or an impulse comes from the wheel speed sensor 6 21 3 Messages on the combination instrument 401901 01 Possible states Battery voltage of the combination instrument The battery voltage of the combination instrument is too low Change combination instrument battery ...

Page 47: ...T display flashes Info Combination settings can be made once the set up menu is active If no setting has been made the set up menu automatically changes to the next menu item after 5 seconds 6 21 5 Setting the kilometers or miles Info If the unit is changed the value is retained and converted accordingly Make the setting according to the country Condition The motorcycle is stationary ...

Page 48: ...ment automatically changes to the next menu item 6 21 6 Setting the clock Condition The motorcycle is stationary 401911 01 Press and hold both buttons for 3 5 seconds The Setup menu is displayed The UNIT display flashes Wait for the menu of the clock to flash Press the left or right button to select the 24 h display or 12 h display for the clock Wait for 5 seconds The setting is adopted and the co...

Page 49: ... is adopted and the combination instru ment automatically changes to the next menu item 6 21 7 Setting the service display Condition The motorcycle is stationary 401913 01 Press and hold both buttons for 3 5 seconds The Setup menu is displayed The UNIT display flashes Wait for the menu of the service display to flash Set the service Guideline Service display switched off Shortening the service int...

Page 50: ...LS 48 The value decreases Extending the service interval Press the right button The value increases 401914 01 Switching off the service interval display Press and hold the left button off appears in the display ...

Page 51: ...ince the last reset such as between two refueling stops Info If the value of 39999 9 is exceeded DST is automatically reset to 0 0 Press the left button briefly Next display mode Press the left button for 3 5 seconds DST can be preset to a value between 0 0 and 39999 9 by pressing the buttons Press the right button briefly Next display mode Press the right button for 3 5 sec onds DST is reset to 0...

Page 52: ... since the last reset such as between two refueling stops Info If the value of 39999 9 is exceeded DST2 is automatically reset to 0 0 Press the left button briefly Next display mode Press the left button for 3 5 seconds DST2 can be preset to a value between 0 0 and 39999 9 by pressing the buttons Press the right button briefly Next display mode Press the right button for 3 5 sec onds DST2 is reset...

Page 53: ...s the average speed since the last reset ART shows the operating hours ODO shows the total distance covered Press the left button briefly Next display mode Press the left button for 3 5 seconds The OPEN END WRENCH SYMBOL shows the remaining operating hours until the next service is due Press the right button briefly Next display mode Press the right button for 3 5 sec onds AVG is reset to 0 0 ...

Page 54: ...met boots gloves as well as trousers and a jacket with protectors on all rides Always wear protective clothing that is in good condition and meets the legal regulations Warning Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling charac teristic Different tire tread patterns can make the vehicle significantly more difficult to control Make sure that only...

Page 55: ... foot off the foot brake lever when you are not braking Info When using your vehicle remember that others may feel disturbed by excessive noise Make sure that the pre sales inspection work has been carried out by an authorized KTM workshop You receive a delivery certificate and the Service Manufacturer Warranty Booklet at vehicle handover Before riding for the first time read the entire Owner s Ma...

Page 56: ...ndlebar firmly with both hands and keep your feet on the footrests when riding Run the engine in p 54 7 2 Running in the engine During the run in phase do not exceed the specified vehicle speed in the respective gear Guideline During the first 1 000 km 620 mi Maximum speed per gear First gear 45 km h 28 mph Second gear 65 km h 40 4 mph Third gear 85 km h 52 8 mph Fourth gear 105 km h 65 2 mph Fift...

Page 57: ... of accidents Improper mounting of cases or the tank rucksack impairs the handling characteris tic Mount and secure cases and tank rucksack according to the manufacturer s instructions Warning Danger of accidents Unstable handling 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 bag...

Page 58: ... to your payload Warning Danger of accidents Pieces of luggage which have slipped impair the handling characteristic Check that your luggage is fixed properly at regular intervals Warning Fire hazard The hot exhaust system may burn luggage Fasten your luggage in such a way that it cannot be burned or singed by the hot exhaust system If you carry luggage make sure you secure it firmly as close as p...

Page 59: ...PREPARING FOR USE 7 57 Guideline Maximum permissible overall weight 350 kg 772 lb Maximum permissible front axle load 150 kg 331 lb Maximum permissible rear axle load 200 kg 441 lb ...

Page 60: ...r brake fluid level p 144 Check the front brake linings p 135 Check the rear brake linings p 147 Check that the brake system is functioning properly Check the coolant level p 202 Check the chain for dirt p 109 Check the chain tension p 111 Check the tire condition p 165 Check tire pressure p 167 Check the settings of all controls and ensure that they can be operated smoothly Check that the electri...

Page 61: ...ective exhaust extraction when starting or running the engine in an enclosed space Caution Danger of accidents Electronic components and safety devices will be damaged if the 12 V battery is dis charged or missing Never operate the vehicle with a discharged 12 V battery or without a 12 V battery Note Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine ...

Page 62: ... After you switch on the ignition you can hear the fuel pump working for about two seconds The function check of the combination instrument is run at the same time The ABS warning lamp lights up and goes back out after starting off Shift the transmission to neutral position The green idle indicator lamp N lights up Press the electric starter button ...

Page 63: ...conds Wait for a least 5 seconds before trying again This motorcycle is equipped with a safety starting sys tem 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 shift into gear and release the clutch the engine stops Take the weight off the side stand and swing it back up with your foot a...

Page 64: ...tched off com pletely the vehicle s approval for road use is invali dated Only operate the vehicle in closed off areas remote from public road traffic if the ABS is switched off completely Press and hold the button 1 for 3 5 seconds The ABS warning lamp lights up ABS is deacti vated 8 3 Starting off Pull the clutch lever engage 1st gear release the clutch lever slowly and simultaneously open the t...

Page 65: ...g Danger of accidents If you change down at high engine speed the rear wheel blocks and the engine races Do not change into a low gear at high engine speed Warning Danger of accidents An incorrect ignition key position causes malfunctions Do not change the ignition key position while driving Warning Danger of accidents Adjustments to the vehicle distract attention from traffic activity Make all ad...

Page 66: ...ning Danger of accidents A risky riding style constitutes a major risk Comply with traffic regulations and ride defensively and with foresight to detect sources of danger as early as possible Warning Danger of accidents Cold tires have reduced road grip Ride the first miles carefully on every journey at moderate speed until the tires reach operating tem perature Warning Danger of accidents New tir...

Page 67: ...oads Warning Danger of accidents Pieces of luggage which have slipped impair the handling characteristic Check that your luggage is fixed properly at regular intervals Warning Danger of accidents A fall can damage the vehicle more seriously than it may first appear Check the vehicle after a fall as you do when preparing for use Note Engine damage Unfiltered intake air has a negative effect on the ...

Page 68: ...n stop immediately switch off the engine park the vehicle prop erly and contact an authorized KTM workshop 401950 11 Shift into a higher gear when conditions allow incline road situation etc Release throttle while simultaneously pulling the clutch lever shift into the next gear release the clutch lever and open the throttle Info The gear positions can be seen in the figure The neu tral or idle pos...

Page 69: ...ver and press the electric starter button The transmission must not be shifted into neutral Switch off the engine if you are likely to be running at idle speed or stationary for a long time Avoid frequent and lengthy slipping of the clutch This causes the engine oil engine and cooling system to heat up Ride at a low engine speed instead of at a high engine speed with a slipping clutch If the oil p...

Page 70: ...ch lever Guideline Minimum speed before gear change First gear to second gear 30 km h 18 6 mph Second gear to third gear 40 km h 24 9 mph Third gear to fourth gear 45 km h 28 mph Fourth gear to fifth gear 50 km h 31 1 mph Fifth gear to sixth gear 55 km h 34 2 mph Quickshifter allows you to shift down in the speed range shown without pulling the clutch lever ...

Page 71: ... speed before gear change Sixth gear to fifth gear 165 km h 102 5 mph Fifth gear to fourth gear 145 km h 90 1 mph Fourth gear to third gear 120 km h 74 6 mph Third gear to second gear 90 km h 55 9 mph Second gear to first gear 60 km h 37 3 mph ...

Page 72: ...d you can shift up and down without actuating the clutch Because there is no need to close the throttle grip uninterrupted gear shifts are possible The quickshifter uses the shifter shaft position to check whether or not a shift should be initiated and sends a corresponding signal to the engine control ...

Page 73: ...ay spin during strong acceleration and on surfaces with low grip resulting in a risk of crashing After the ignition is switched on motorcycle traction con trol is enabled again The motorcycle traction control MTC is switched on and off on the left combination switch using the TC button Info When the motorcycle traction control is active the TC indi cator lamp flashes When motorcycle traction contr...

Page 74: ...ted Your authorized KTM workshop will be glad to help Warning Danger of accidents The brake system fails in the event of overheating If the foot brake lever is not released the brake linings drag continuously Take your foot off the foot brake lever when you are not braking Warning Danger of accidents Higher total weight increases the stopping distance Take the longer stopping distance into account...

Page 75: ...nts The rear wheel can lock due to the engine braking effect Pull in the clutch if you perform emergency or full braking or if you brake on a slippery ground When braking release the throttle and apply the front and rear brakes at the same time Info When the ABS is enabled you can achieve maximum braking power even on low grip surfaces such as sandy wet or slippery terrain without locking of the w...

Page 76: ...ignition key if you leave the vehicle unattended Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch any parts such as the exhaust system radiator engine shock absorber or brake system before the vehicle parts have cooled down Let the vehicle parts cool down before you perform any work on the vehicle Note Material damage The vehicle may be dama...

Page 77: ...he ignition remains switched on at the ignition lock power continues to flow to most power consumers This discharges the 12 V battery You should therefore always switch off the engine with the ignition lock the emergency OFF switch is intended for emergencies only Park the motorcycle on a firm surface Swing the side stand forward with your foot as far as it will go and lean the vehicle on it Lock ...

Page 78: ... hazard Hot vehicle components pose a fire hazard and explosion risk Do not park the vehicle near to materials which are highly flammable or explosive Allow the vehicle to cool down before covering it 401448 01 Switch off the engine and remove the ignition key Use tension belts or other suitable devices to secure the motorcycle against accidents or falling over ...

Page 79: ...lled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel ...

Page 80: ...t This will result in problems with the fuel system Refuel only with clean fuel that meets the specified standards Your authorized KTM workshop will be glad to help Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system ...

Page 81: ...he engine Open fuel tank filler cap p 41 Fill the fuel tank with fuel up to level A Guideline Dimension A 20 mm 0 79 in Total fuel tank capacity approx 13 5 l 3 57 US gal Super unleaded ROZ 95 RON 95 PON 91 p 258 Close the fuel tank filler cap p 43 ...

Page 82: ...p to date service schedule can always be found on KTM Dealer net Your authorized KTM dealer will be happy to advise you 9 2 Required work after every sporting use Every two years Every year every 20 000 km 12 400 mi every 10 000 km 6 200 mi after 1 000 km 620 mi Read out the fault memory using the KTM diagnostics tool Check that the electrical system is functioning properly Change the engine oil a...

Page 83: ...4 Check correct the fluid level of hydraulic clutch p 122 Check the free travel of the foot brake lever p 141 Check the shock absorber and fork for leaks Perform a fork service and shock absorber service as needed and depending on how the vehicle is used Clean the dust boots of the fork legs p 93 Check the steering head bearing play p 97 Check the tire condition p 165 Check tire pressure p 167 Che...

Page 84: ... p 199 Check the cables for damage and for routing without kinks Change the air filter Clean the air filter box Check the fuel pressure Check the headlight setting p 192 Check that the radiator fan is functioning properly Final check Check the vehicle is roadworthy and take a test ride Read out the fault memory using the KTM diagnostics tool after a test ride Make the service entry in KTM Dealer n...

Page 85: ... the link fork Check the link fork bearing for play Check the wheel bearing for play Grease all moving parts e g side stand hand lever chain etc and check for smooth operation Check all hoses e g fuel cooling bleeder drainage hoses etc and sleeves for cracking tightness and correct routing Check the screws and nuts for tightness Change the coolant p 207 One time interval Periodic interval ...

Page 86: ...The table is located on the underside of the front rider s seat These adjustments should be understood as a guideline and should always be the basis for one s own personal suspension setting Do not change the adjustments at random as otherwise the riding characteristics could deteriorate particularly at high speeds 10 2 Adjusting the compression damping of the fork Info The hydraulic compression d...

Page 87: ... is located in left fork leg COMP white adjusting screw The rebound damping is located in right fork leg REB red adjusting screw Turn counterclockwise by the number of clicks corresponding to the fork type Guideline Compression damping Comfort 10 clicks Standard 15 clicks Sport 20 clicks Full payload 20 clicks Info Turn clockwise to increase damping turn counterclock wise to reduce damping ...

Page 88: ...ill go Info Adjusting screw 1 is located at the upper end of the right fork leg The rebound damping is located in right fork leg REB red adjusting screw The compression damping is located in left fork leg COMP white adjusting screw Turn counterclockwise by the number of clicks corresponding to the fork type Guideline Rebound damping Comfort 10 clicks Standard 15 clicks Sport 20 clicks Full payload...

Page 89: ...ly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses slowly These two ranges can be adjusted separately although the transition between high speed and low speed is grad ual Thus modifications in the high speed range affect the compression damping in the low speed range and vice versa 10 5 Adjusting the low speed compression dam...

Page 90: ...se with a screwdriver as far as the last perceptible click Info Do not loosen fitting 2 Turn counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Low speed compression damping Comfort 25 clicks Standard 20 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclock wise to reduce damping ...

Page 91: ...sorber is filled with highly compressed nitrogen Please follow the description provided Your authorized KTM workshop will be glad to help Info The effect of the high speed setting can be seen in fast compression of the shock absorber S03335 11 Turn adjusting screw 1 all the way clockwise with a socket wrench Info Do not loosen fitting 2 Turn counterclockwise by the number of turns corresponding to...

Page 92: ...amping turn counterclock wise to reduce damping 10 7 Adjusting the rebound damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized KTM workshop will be glad to help ...

Page 93: ...erceptible click Turn counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 25 clicks Standard 20 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclock wise to reduce damping ...

Page 94: ... vehicle on a firm and level surface 401942 01 Use the motor guard underneath the motor to raise the vehicle Neither wheel is in contact with the ground Secure the motorcycle against falling over 11 2 Removing the motorcycle from the lift stand Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface ...

Page 95: ...he fork legs Preparatory work Raise the motorcycle with a lift stand p 92 Remove fork protector p 95 S03371 10 Main work Push dust boots 1 of both fork legs downward Info The dust boots remove dust and coarse dirt particles from the inside fork tubes Over time dirt can accumu late behind the dust boots If this dirt is not removed the oil seals behind can start to leak ...

Page 96: ...cs free of oil and grease Clean the brake discs with brake cleaner when nec essary Clean and oil the dust boots and inner fork tubes of both fork legs Universal oil spray p 260 Press the dust boots back into the installation position Remove the excess oil Finishing work Install the fork protector p 95 Remove the motorcycle from the lift stand p 92 ...

Page 97: ...ro tector Remove screws 2 on the right fork leg Take off the fork pro tector 11 5 Installing the fork protector S03364 11 Position the left fork protector Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position brake line wiring harness and clamp Mount and tighten screws 2 Position the right fork protector Mount and tighten screws 1 ...

Page 98: ...ork legs Preparatory work Raise the motorcycle with a lift stand p 92 M01576 10 Main work Release bleeder screws 1 Any excess pressure escapes from the interior of the fork Tighten the bleeder screws Info Carry out this operation on both fork legs Finishing work Remove the motorcycle from the lift stand p 92 ...

Page 99: ...le is operated for a lengthy period with play in the steering head bearing the bearings and the bearing seats in the frame can become damaged over time Preparatory work Raise the motorcycle with a lift stand p 92 400738 11 Main work Move the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel Play should not be detectable on the steering head bearing I...

Page 100: ...eck the steering head bearing and adjust if neces sary Finishing work Remove the motorcycle from the lift stand p 92 11 8 Adjusting the steering head bearing play Preparatory work Raise the motorcycle with a lift stand p 92 R05381 10 Main work Loosen screws 1 Loosen screw 2 Loosen and retighten screw 3 Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on...

Page 101: ...2 5 lbf ft Tighten screw 2 Guideline Screw steering stem M8 20 Nm 14 8 lbf ft Finishing work Check the steering head bearing play p 97 Remove the motorcycle from the lift stand p 92 11 9 Removing the seat S03336 10 Pull on loop 1 and raise the rear of the seat Pull the seat back and lift it off ...

Page 102: ... on to bushings 2 lower the seat at the rear and push it forward Push locking pin 3 into lock housing 4 and push the back of the seat down until the locking pin locks in place with an audible click Check that the seat is correctly mounted 11 11 Removing the tool set Preparatory work Remove the seat p 99 ...

Page 103: ...t side cover from the rubber bushing in area A Remove the left side cover upwards from the bushing in area B Take off the left side cover from the front Open the tool set compartment and take out tool set 1 11 12 Storing the tool set Preparatory work Remove the seat p 99 ...

Page 104: ...tore the tool set in the tool set compartment Position the left side cover using holding lugs 1 on bushings 2 and push towards the rear and in the rear section down ward Press the side cover into rubber bushing 3 in area A Finishing work Mount the seat p 100 ...

Page 105: ... Preparatory work Remove the seat p 99 S03283 10 Main work Remove the left side cover from the rubber bushing in area A Remove the left side cover upwards from the bushing in area B Take off the left side cover from the front Repeat these steps on the opposite side ...

Page 106: ... Main work Position the left side cover using holding lugs 1 on bushings 2 and push towards the rear and in the rear section down ward Press the left side cover into the rubber bushing 3 in area A Repeat these steps on the opposite side Finishing work Mount the seat p 100 ...

Page 107: ...ICE WORK ON THE CHASSIS 11 105 11 15 Removing the front fender Preparatory work Remove the headlight mask with the headlight p 186 S03291 10 Main work Remove screws 1 Remove screws 2 and take off the fender ...

Page 108: ...d tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the headlight mask with the headlight p 187 Check the headlight setting p 192 11 17 Removing the air filter Preparatory work Remove the seat p 99 ...

Page 109: ...e the upper part of the air filter box 2 S03339 10 Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine Dust and dirt will enter the engine without an air filter Never start to use the vehicle without an air filter Remove air filter 3 ...

Page 110: ...t the air filter box along the entire sealing surface A If the air filter is not mounted correctly dust and dirt may enter the engine and result in damage Hook air filter box top 2 into the front of the air filter box and swing down S03338 11 Mount and tighten screws 3 Guideline Screw upper part of the air filter box M6 2 Nm 1 5 lbf ft Finishing work Mount the seat p 100 ...

Page 111: ...09 11 20 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip Remove lubricants from the tires using a suitable cleaning agent Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary ...

Page 112: ...h the applicable regulations Info The service life of the chain depends largely on its maintenance Preparatory work Raise the motorcycle with a lift stand p 92 400725 01 Main work Rinse off loose dirt with a soft jet of water Remove old grease residue with chain cleaner Chain cleaner p 259 After drying apply chain spray Off road chain spray p 259 Finishing work Remove the motorcycle from the lift ...

Page 113: ... too much the chain engine sprocket rear sprocket transmission and rear wheel bearings wear more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification ...

Page 114: ...at a distance B from the chain slid ing guard and determine chain tension A Info Top chain section C must be taut Chain wear is not always even Repeat this measure ment at different chain positions Chain tension 5 mm 0 2 in Distance to chain sliding guard 30 mm 1 18 in If the chain tension does not meet the specification Adjust the chain tension p 113 ...

Page 115: ...ine sprocket rear sprocket transmission and rear wheel bearings wear more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Check the chain...

Page 116: ...at the markings on the left and right chain adjusters 4 are in the same position relative to the reference marks A The rear wheel is then correctly aligned Info The top chain section must be taut Chain wear is not always even Repeat this measure ment at different chain positions Tighten nuts 2 Make sure that chain adjusters 4 are fitted correctly on adjusting screws 3 Tighten nut 1 Guideline Nut r...

Page 117: ... Raise the motorcycle with a lift stand p 92 100132 10 Main work Shift the transmission into neutral Check the chain rear sprocket and engine sprocket for wear If the chain rear sprocket or engine sprocket is worn Change the drivetrain kit Info The engine sprocket rear sprocket and chain should always be replaced together ...

Page 118: ...fo Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance B from 18 chain rollers at the longest chain section 272 mm 10 71 in If distance B is greater than the specified measurement Change the drivetrain kit Info When a new chain is mounted the rear sprocket and engine sprocket should also be changed New chains wear out faster on an old w...

Page 119: ...dge of the chain pins is in line with or below the chain sliding guard Replace the chain sliding guard Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighten screws on the chain sliding guard Guideline Screw chain sliding guard M6 8 Nm 5 9 lbf ft Loctite 243 ...

Page 120: ...ower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten screw on the chain sliding piece Guideline Screw chain slid ing piece M8 15 Nm 11 1 lbf ft ...

Page 121: ...e chain guide If the light part of the chain guide is worn Change the chain guide 101068 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the screws on the chain guide Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Remove the motorcycle from the lift stand p 92 ...

Page 122: ...ndition Number of teeth 44 teeth Insert nut 3 in hole A Position the chain guide Mount and tighten screws 1 and 2 Guideline Screw chain guide M6 8 Nm 5 9 lbf ft Condition Number of teeth 45 teeth Insert nut 3 in hole B Position the chain guide Mount and tighten screws 1 and 2 Guideline Screw chain guide M6 8 Nm 5 9 lbf ft ...

Page 123: ...urning adjusting screw 1 Info Do not make any adjustments while riding Push the clutch lever forward and turn the adjusting wheel The range of adjustment is limited Only turn the adjusting screw by hand and do not use force When adjusting the clutch lever make sure to leave a mini mum clearance to other parts of the vehicle Guideline Minimum clearance 5 mm 0 2 in ...

Page 124: ...othing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Note Environmental hazard Hazardous substances cause environmental dama...

Page 125: ...ted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container Move the clutch fluid reservoir mounted on the handlebar to a horizontal position S02197 10 Remove screws 1 Take off cover 2 with membrane 3 Check the fluid level Fluid level below container rim 4 mm 0 16 in If the fluid level does not meet specifications Correct the fluid level of the hydraulic clutch Brake flu...

Page 126: ...HE CHASSIS 124 Info Clean up the overflowed or spilled brake fluid immedi ately with water 11 27 Removing engine guard S03365 10 Remove screws 1 on both sides Pull the engine guard forward out of the holders and remove it ...

Page 127: ...SIS 11 125 11 28 Installing the engine guard S03365 11 Slide the engine guard into holders 1 at the rear Position the engine guard Mount and tighten screws 2 on both sides Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 128: ...in with the front brake applied away from public road traffic if the ABS is switched off Do not make any changes to the suspension travel Only use spare parts on the brake system which have been approved and recommended by KTM Only use tires wheels approved by KTM with the corre sponding speed index Maintain specified tire pressure Ensure that service work and repairs are performed professionally ...

Page 129: ... like a conventional brake system without ABS When the ABS con trol unit detects a locking tendency in a wheel ABS begins reg ulating the brake pressure The control function causes a slight pulsing of the hand and foot brake levers The ABS warning lamp 3 must light up after the ignition is switched on and go out after starting off If it does not go out after starting off or if it lights up while r...

Page 130: ... insurance coverage If the ABS is switched off completely the vehicle s approval for road use is invalidated Only operate the vehicle in closed off areas remote from public road traffic if the ABS is switched off completely The 3 button can be used to switch the ABS off manually see Starting Info The motorcycle has an additional 5 D sensor The 5 D sen sor makes the ABS control dependent on the ang...

Page 131: ...turning adjusting wheel 1 Info Do not make any adjustments while riding Push the hand brake lever forward and turn the adjust ing wheel The range of adjustment is limited Only turn the adjusting screw by hand and do not use force When adjusting the brake lever maintain a minimum clear ance to other parts of the vehicle Guideline Minimum clearance 5 mm 0 2 in ...

Page 132: ...he front and rear brake disc thickness at multiple points for the dimension A Info Wear will reduce the thickness of the brake disc at con tact surface 1 of the brake linings Brake discs wear limit front 4 5 mm 0 177 in rear 4 5 mm 0 177 in If the brake disc thickness is less than the specified value Change the brake disc Check the front and rear brake discs for damage cracking and deformation If ...

Page 133: ...r the specified value the brake system is leaking or the brake linings are worn down Check the brake system and do not continue riding until the problem is eliminated Your authorized KTM workshop will be glad to help Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your ...

Page 134: ...ke fluid p 132 12 5 Adding the front brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake system and do not continue riding until the problem is eliminated Your authorized KTM worksh...

Page 135: ... Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your authorized KTM workshop will be glad to ...

Page 136: ... use clean brake fluid from a sealed container Preparatory work Check the front brake linings p 135 S03342 10 Main work Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Take off cover 2 with membrane 3 Add brake fluid to level A Guideline Level A brake fluid level below reservoir rim 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 256 Position the cover with...

Page 137: ...ct Ensure that worn out brake linings are replaced immediately Your authorized KTM workshop will be glad to help Warning Danger of accidents Damaged brake discs reduce the braking effect If the brake linings are not changed in time the brake lining carriers grind against the brake disc As a consequence the braking effect is greatly reduced and the brake discs are destroyed Check the brake linings ...

Page 138: ...ont brake linings p 136 Check the brake linings for damage and cracking If there is wear or tearing Change the front brake linings p 136 12 7 Changing the front brake linings Warning Danger of accidents Incorrect servicing will cause the brake system to fail Ensure that service work and repairs are performed professionally Your authorized KTM workshop will be glad to help ...

Page 139: ...kin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your authorized KTM workshop will be glad ...

Page 140: ... guaranteed In this case the vehicle no longer corresponds to its condition at delivery and the warranty shall be void Only use brake linings approved and recommended by KTM Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 bra...

Page 141: ...brake disc to push back the brake pistons Ensure that brake fluid does not flow out of the brake fluid reservoir extract some if necessary Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons 400418 11 Remove cotter pin 4 remove pin 5 toward the right by striking it and remove the brake linings Clean the brake caliper and the brake caliper b...

Page 142: ...ys change the brake linings in pairs Operate the hand brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point S03342 12 Correct the brake fluid quantity to level A Guideline Dimension A 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 256 Position the cover with the membrane Mount and tighten the screws Info Clean up the overflowed or spilled brake f...

Page 143: ...in accordance with the specification 402027 10 Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel A Guideline Free travel 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 resistance when you activate the foot brake lever ...

Page 144: ...lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification ...

Page 145: ... 2 accord ingly Info The range of adjustment is limited The screw must be screwed into the footrest bracket by at least four turns Position foot brake cylinder 4 so that the foot brake lever has the necessary free travel Mount and tighten fittings 3 Guideline Screw connection foot brake cylinder M6 10 Nm 7 4 lbf ft Check the free travel of the foot brake lever p 141 Tighten nut 1 ...

Page 146: ...and do not continue riding until the problem is eliminated Your authorized KTM workshop will be glad to help Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your authorized KTM workshop will be glad to help S03343 10 Stand the vehicle upright Check the brake fluid level...

Page 147: ...ll be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the s...

Page 148: ...substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean br...

Page 149: ...fluid DOT 4 DOT 5 1 p 256 Mount screw cap with washer and membrane Info Clean up the overflowed or spilled brake fluid immedi ately with water 12 12 Checking the rear brake linings Warning Danger of accidents Worn out brake linings reduce the braking effect Ensure that worn out brake linings are replaced immediately Your authorized KTM workshop will be glad to help ...

Page 150: ...962 01 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings p 148 Check the brake linings for damage and cracking If there is wear or tearing Change the rear brake linings p 148 12 13 Changing the rear brake linings Warning Danger of accidents Incorrect servicing will cause the brake system to...

Page 151: ...kin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your authorized KTM workshop will be glad ...

Page 152: ... guaranteed In this case the vehicle no longer corresponds to its condition at delivery and the warranty shall be void Only use brake linings approved and recommended by KTM Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Never use DOT 5 bra...

Page 153: ... the brake piston Ensure that brake fluid does not flow out of the brake fluid reservoir extract some if necessary Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston B01962 10 Remove cotter pin 3 remove pin 4 toward the left by strik ing it and remove the brake linings Clean the brake caliper and the brake caliper bracket ...

Page 154: ...mount the cot ter pins Info Always change the brake linings in pairs Operate the foot brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point Adjust the brake fluid level to the MAX marking Brake fluid DOT 4 DOT 5 1 p 256 Mount screw cap with washer and membrane Info Clean up the overflowed or spilled brake fluid immedi ately with water ...

Page 155: ...nually press the brake caliper toward the brake disc to push back the brake pistons Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons S03369 10 Loosen screw 1 by several rotations Loosen screws 2 Press on screw 1 to push the wheel spindle out of the axle clamp Remove screw 1 ...

Page 156: ...ce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork Info Do not actuate the hand brake lever when the front wheel is removed S03368 10 Remove spacers 3 ...

Page 157: ...lways keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary H00935 10 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change front wheel bearing Clean and grease shaft seal rings 1 and contact surfaces A of the spacers Long life grease p 259 Insert the spacers ...

Page 158: ...ioned Mount and tighten screw 2 Guideline Screw front wheel spindle M24x1 5 45 Nm 33 2 lbf ft Operate the hand brake lever several times until the brake lin ings are seated correctly against the brake disc Remove the motorcycle from the lift stand p 92 Operate the front brake and compress the fork a few times firmly The fork legs straighten Tighten screws 3 Guideline Screw fork stub M8 15 Nm 11 1 ...

Page 159: ...WHEELS TIRES 13 157 13 3 Removing the rear wheel Preparatory work Raise the motorcycle with a lift stand p 92 R05230 10 Main work Take the brake line out of the guide ...

Page 160: ...here the chain adjuster is no longer in contact with the adjusting screw Push the rear wheel forward as far as possible and take the chain off the rear sprocket Info Cover the components to protect them against damage Hold the rear wheel and remove the wheel spindle Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc...

Page 161: ... wheel is removed R04972 10 Remove spacer 6 13 4 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary ...

Page 162: ...veral times before going on a ride until you can feel a firm pressure point Main work Check the rear hub damping rubber pieces p 163 V01510 10 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change the rear wheel bearing Clean and grease shaft seal ring 1 and contact surface A of the spacer Long life grease p 259 Insert a spacer ...

Page 163: ...ly positioned Push the rear wheel forward as far as possible and lay chain on the rear sprocket Mount wheel spindle 3 and chain adjuster 4 Mount nut 2 but do not tighten it yet Make sure that chain adjusters 4 are fitted correctly on adjusting screws 5 Guideline In order for the rear wheel to be correctly aligned the mark ings on the left and right chain adjusters must be in the same position rela...

Page 164: ... and tighten screw 7 Guideline Screw wheel speed sensor M6 6 Nm 4 4 lbf ft R05230 10 Position the brake line in the guide Operate the foot brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand p 92 Check the chain tension p 111 ...

Page 165: ...nged in time the rear sprocket carrier and the rear hub will be damaged Preparatory work Raise the motorcycle with a lift stand p 92 Remove the rear wheel p 157 V00512 10 Main work Check bearing 1 If the bearing is damaged or worn Change the bearing of the rear sprocket carrier Check damping rubber pieces 2 of the rear hub for damage and wear If the damping rubber pieces of the rear hub are damage...

Page 166: ...and try to turn the rear sprocket with your hand Info Measure the play on the outside of the rear sprocket Play of damping rubber pieces on rear wheel 5 mm 0 2 in If clearance A is larger than the specified value Change all the damping rubber pieces of the rear hub Finishing work Install the rear wheel p 159 Remove the motorcycle from the lift stand p 92 Check the chain tension p 111 ...

Page 167: ...fferent tire tread patterns can make the vehicle significantly more difficult to control Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel Warning Danger of accidents Non approved or non recommended tires and wheels impact the handling character istic Only use tires wheels approved by KTM with the corresponding speed index Warning Danger of accident...

Page 168: ...dling characteristics especially on wet surfaces 400602 10 Check the front and rear tires for cuts run in objects and other damage If the tires have cuts run in objects or other damage Change the tires Check the tread depth Info Adhere to the legally required minimum tread depth Minimum tread depth 2 mm 0 08 in If the tread depth is less than the minimum tread depth Change the tires ...

Page 169: ...week of manufacture and the last two digits the year of manu facture KTM recommends that the tires be changed after 5 years at the latest regardless of the actual state of wear If the tires are more than 5 years old Change the tires 13 7 Checking tire pressure Info Low tire pressure leads to abnormal wear and overheating of the tire Correct tire pressure ensures optimal riding comfort and maximum ...

Page 170: ...pressure offroad solo front 1 5 bar 22 psi rear 1 5 bar 22 psi Tire pressure road solo front 1 8 bar 26 psi rear 1 8 bar 26 psi Tire pressure with passenger full payload front 2 2 bar 32 psi rear 2 2 bar 32 psi If the tire pressure does not meet specifications Correct the tire pressure Mount the protection cap ...

Page 171: ...l form in the wheel Other spokes will become looser as a result Check spoke tension regularly and in particular on a new vehicle Your authorized KTM workshop will be glad to help 400694 01 Strike each spoke briefly using a screwdriver blade Info The frequency of the sound depends on the spoke length and spoke diameter If spokes of the same length and diameter vibrate with a different tone this is ...

Page 172: ... types of damage Observe the instructions and specifications of the manufacturer of the tire repair spray After repairing a tire with tire repair spray ride slowly and carefully Ride no further than to the nearest workshop and have the tire changed Tire repair spray should only be used in an emergency We recommend transporting the broken down vehicle to the near est workshop instead of using tire ...

Page 173: ...ery acid and battery gases Keep sparks or open flames away from the 12 V battery Only charge 12 V batteries in well ventilated rooms Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and battery gases get into the eyes Preparatory work Switch off the ignition ...

Page 174: ...work Pull engine electronics control unit 1 off the holder and set it to one side S03293 10 Remove screws 2 Pull the retaining bracket forward and remove it Disconnect negative cable 3 from the 12 V battery Take off positive terminal cover 4 ...

Page 175: ...e motorcycle with a discharged 12 V battery or without a 12 V battery In both cases elec trical components and safety devices can be damaged The vehicle will therefore no longer be roadworthy 14 2 Installing the 12 V battery S03294 01 Main work Insert the 12 V battery into the battery compartment with the terminals facing to the rear 12 V battery YTZ10S p 246 ...

Page 176: ... Screw battery termi nal M6 4 5 Nm 3 32 lbf ft S03296 10 Position positive terminal cover 5 Position washer 6 and negative cable 7 and mount and tighten the screw Guideline Screw battery termi nal M6 4 5 Nm 3 32 lbf ft Position retaining bracket 8 and mount and tighten screws 9 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 177: ...ELECTRICAL SYSTEM 14 175 S03297 10 Position the engine electronics control unit bk Finishing work Mount the seat p 100 Set the clock p 46 ...

Page 178: ...ed area immediately with plenty of water in the event of contact with the skin Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and battery gases get into the eyes Note Environmental hazard 12 V batteries contain environmentally hazardous materials Do not dispose of 12 V batteries as household waste Dispose of 12 V batteries at a collection point for u...

Page 179: ...trolyte escapes through the safety valves This reduces the capacity of the 12 V battery If the 12 V battery is depleted from starting the vehicle repeatedly the battery must be charged immedi ately If the 12 V battery is left in a discharged state for an extended period it will become deeply discharged and sulfating occurs destroying the battery The 12 V battery is maintenance free i e the acid le...

Page 180: ...ion you cannot overcharge the 12 V battery with this device Info Never remove cover 1 Charge the 12 V battery to a maximum of 10 of the capacity specified on battery housing 2 Switch off the battery charger after charging and disconnect it from the 12 V battery Guideline The charging current charging voltage and charging time must not be exceeded Recharge the 12 V battery regularly when the motorc...

Page 181: ...trical system Only use fuses with the required ampere value Do not bypass or repair fuses Info The main fuse protects all power consumers of the vehicle It is in the housing of the starter relay next to the 12 V battery Preparatory work Switch off the ignition by turning the ignition key to the posi tion Remove the seat p 99 ...

Page 182: ...le nose pliers Info A faulty fuse has a burned out fuse wire A A spare fuse 3 is located in the starter relay Insert a new main fuse Fuse 58011109130 p 246 Info Insert a new spare fuse into the starter relay to have it available when needed Check that the electrical system is functioning properly Mount the protection caps ...

Page 183: ...s or repair fuses Info Two fuses for the ABS are located under the 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 off the ignition by turning the ignition key to the posi tion Remove the seat p 99 Pull the engine electronics control unit off of the holder and set it to ...

Page 184: ...rt a new fuse Fuse 58011109115 p 246 Mount the protection cap S03300 11 To change the fuse of the ABS return pump Take off protection cap 2 and remove the fuse Insert a new fuse Fuse 58011109125 p 246 Mount the protection cap Finishing work Mount the battery support Position the engine electronics control unit Mount the seat p 100 ...

Page 185: ...al power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat Preparatory work Switch off the ignition by turning the ignition key to the posi tion Remove the seat p 99 S03301 10 Main work Open fuse box cover 1 ...

Page 186: ...unit Fuse 3 10 A fuel pump Fuse 4 10 A radiator fan Fuse 5 10 A horn brake light turn signal Fuse 6 15 A high beam low beam position light tail light license plate lamp Fuse 7 10 A for auxiliary equipment ACC 1 permanent positive Fuse 8 10 A for auxiliary equipment ACC 2 ignition plus USB charging socket Fuse 9 10 A ABS Fuse 10 not assigned Fuse SPARE 10 A 15 A spare fuses Info A faulty fuse has a...

Page 187: ...d ampere value Do not bypass or repair fuses Insert a spare fuse with the correct rating Fuse 75011088010 p 246 Fuse 75011088015 p 246 Tip Replace the spare fuse in the fuse box so that it is available if needed Check that the power consumer is functioning properly Close the fuse box cover Finishing work Mount the seat p 100 ...

Page 188: ...e headlight Switch off the ignition by turning the ignition key to the posi tion S03303 10 Cover the fender with a cloth Remove screws 1 on both sides Tip the headlight mask forward S03304 10 Disconnect plug in connector 2 of the headlight Take off the headlight mask ...

Page 189: ...with the headlight S03304 11 Main work Connect plug in connector 1 of the headlight Check that the lighting is functioning properly S03305 10 Remove the cloth from the fender and position the headlight mask Headlight mask engages in the fender on the bushings 2 ...

Page 190: ...hing work Check the headlight setting p 192 14 9 Changing the headlight bulb Note Damage to reflector Grease on the reflector reduces the light intensity Grease on the bulb will evaporate due to the heat and be deposited on the reflector Clean and degrease the bulbs before mounting Do not touch the bulbs with your bare hands Preparatory work Remove the headlight mask with the headlight p 186 ...

Page 191: ...spring bar 3 Remove headlight bulb 4 Insert a new headlight bulb into the headlight housing Headlight H4 socket P43t p 246 Fix the headlight bulb in the headlight using the spring bar Mount the protection cap Plug in the connector Finishing work Install the headlight mask with the headlight p 187 Check the headlight setting p 192 ...

Page 192: ...or reduces the light intensity Grease on the bulb will evaporate due to the heat and be deposited on the reflector Clean and degrease the bulbs before mounting Do not touch the bulbs with your bare hands Preparatory work Remove the headlight mask with the headlight p 186 S03308 10 Main work Remove bulb socket 1 ...

Page 193: ... 2 out of the bulb socket Insert a new position light lamp in the bulb socket Position light W5W socket W2 1x9 5d p 246 Insert the bulb socket in the reflector Finishing work Install the headlight mask with the headlight p 187 Check the headlight setting p 192 ...

Page 194: ... in Position the vehicle vertically at a distance A away from the wall Guideline Distance A 5 m 16 ft The rider now mounts the motorcycle with luggage and passen ger if applicable Switch on the low beam Check the headlight setting The light dark boundary must be exactly on the lower mark ing when the motorcycle is ready to be operated with the rider mounted along with any luggage and a passenger i...

Page 195: ...headlight Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider instructions on how to apply the mark Checking the headlight setting Info If you have a payload you may have to correct the headlight range Tighten screw 1 14 13 Changing the combination instrument battery Preparatory work Remove the headlight mask with the headlight p 186 ...

Page 196: ...14 ELECTRICAL SYSTEM 194 S03312 10 Main work Remove cable tie s 1 Disconnect plug in connector 2 Remove screws 3 ...

Page 197: ...or correct seating S03314 10 Position protection cap 4 and turn all the way clockwise using a coin Press any button on the combination instrument The combination instrument is activated Position the combination instrument in the holder Mount and tighten the screws with washers Join plug in connector 2 Position the wiring harness and fasten it with cable ties 1 Finishing work Install the headlight ...

Page 198: ...tched on USB socket Voltage 5 V Maximum cur rent consump tion 2 1 A 14 15 ACC1 and ACC2 S03334 10 Installation location The power supplies ACC1 1 and ACC2 2 are located behind the headlight mask Info The power supplies are protected by a fuse however this fuse also protects other power consumers The maximum continuous load is therefore significantly lower than the value of the fuse Do not use a st...

Page 199: ...ELECTRICAL SYSTEM 14 197 14 16 Diagnostics connector S02172 10 Diagnostics connector 1 is located under the engine electronics control unit ...

Page 200: ...o flow into compensating tank 3 When the tem perature falls this surplus coolant is sucked back into the cooling system This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions 125 C 257 F 400407 10 The coolant is cooled by the air stream and radiator fan 4 which is activated depending on the temperature The lower the speed the less the...

Page 201: ...r components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plent...

Page 202: ...coolant 25 45 C 13 49 F If the antifreeze in the coolant does not match the speci fied value Correct the antifreeze in the coolant Check the coolant level in the compensating tank The coolant level must be between the two markings If the coolant level does not match the specified value Correct the coolant level Coolant p 256 Mount the cover of the compensating tank ...

Page 203: ...freeze in the coolant does not match the speci fied value Correct the antifreeze in the coolant Check the coolant level in the radiator The radiator must be filled completely If the coolant level does not match the specified value Check the coolant level and the reason for the loss Coolant p 256 Mount the radiator cap ...

Page 204: ...ents of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of wat...

Page 205: ...een the two markings If the coolant level does not match the specified value Correct the coolant level Coolant p 256 S03317 10 Remove radiator cap 2 and check the coolant level in the radiator The radiator must be filled completely If the coolant level does not match the specified value Check the coolant level and the reason for the loss Coolant p 256 Mount the radiator cap ...

Page 206: ...e cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the ...

Page 207: ...illing bleeding the cooling system Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water...

Page 208: ...ensating tank Add coolant up to the marking A Mount the cover of the compensating tank Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Start the engine and let it warm up Stop...

Page 209: ... the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected ...

Page 210: ...ory work Remove engine guard p 124 600616 10 Main work Position the motorcycle vertically Place an appropriate container under the engine Remove screw 1 with the seal ring S03318 11 Remove radiator cap 2 Completely drain the coolant ...

Page 211: ...eal ring Guideline Screw plug water pump drain hole M10x1 15 Nm 11 1 lbf ft S03317 10 Place the motorcycle on a horizontal surface using the side stand Refill with coolant Coolant 1 20 l 1 27 qt Coolant p 256 Completely fill the radiator with coolant Mount radiator cap 2 ...

Page 212: ... are toxic and inhal ing them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Start the engine and let it warm up Stop the engine and allow it to cool down Finishing work Check the coolant level p 202 Install the engine guard p 125 ...

Page 213: ...rive mode can also be changed during the ride H02886 01 Condition Throttle grip closed Press MAP button until the LED displays the desired drive mode Drive mode 1 is ROAD and drive mode 2 is OFFROAD ROAD balanced response OFFROAD direct response Info The drive mode only influences the throttle response The homologated performance is available in both drive modes The traction control allows greater...

Page 214: ...s with low grip Traction control can be switched on or off during the ride S03255 01 Deactivating traction control Condition Throttle grip closed Press and hold the TC button for 3 5 seconds The TC LED lights up when the traction control is deactivated Activating the traction control Condition Throttle grip closed Press and hold the TC button for 3 5 seconds The TC LED does not light up when the t...

Page 215: ...r s boot when in the basic position If the shift lever is permanently touching the boot the transmission will be subject to excessive load this can cause a malfunction of the quickshifter optional 400692 10 Sit on the vehicle in the riding position and determine 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...

Page 216: ...h A of the shift lever and shift shaft Mount shift lever 2 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 shift procedure Mount and tighten screw 1 with the washers Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 ...

Page 217: ...ating temperature Preparatory work Stand the motorcycle upright on a horizontal surface S02208 10 Main work Check the engine oil level Info After switching off the engine wait one minute before checking the level The engine oil must be between the lower and upper edge of the oil level viewer If the engine oil level is not at the specified level Add engine oil p 222 ...

Page 218: ...othing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulations Info Drain the engine oil while the engine is at operating temperature Preparatory work Remo...

Page 219: ...er the engine Remove oil drain plug 1 with the magnet and seal ring Completely drain the engine oil S02209 01 Thoroughly clean the oil drain plug with 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 ...

Page 220: ...ng Pull oil filter 4 out of the oil filter housing Lock ring plier 51012011000 S03321 10 Remove screws 5 Take off oil filter cover 6 with the O ring Pull oil filter 7 out of the oil filter housing Lock ring plier 51012011000 Completely drain the engine oil Thoroughly clean the parts and sealing surface ...

Page 221: ...ENGINE 17 219 S03322 10 Remove screw plug 8 with oil screen 9 and the O rings S03323 10 Remove screw plug bk with oil screen bl and the O rings Completely drain the engine oil Thoroughly clean the parts and sealing surface ...

Page 222: ... with the O rings Mount and tighten screw plug bn with the O ring Guideline Plug oil screen M20x1 5 15 Nm 11 1 lbf ft S03325 10 Position oil screen bo with the O rings Mount and tighten screw plug bp with the O ring Guideline Plug oil screen M20x1 5 15 Nm 11 1 lbf ft ...

Page 223: ...ith the O ring and fill up with engine oil Engine oil 1 70 l 1 8 qt Engine oil SAE 10W 50 p 257 Mount and tighten filler plug ck with the O ring Danger Danger of poisoning Exhaust gases are toxic and inhal ing them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in ...

Page 224: ...ar of the engine H01066 10 Main work Remove filler plug 1 with the O ring and fill up with engine oil Fill engine oil to the middle of the level viewer Engine oil SAE 10W 50 p 257 Info In order to achieve optimal engine oil performance it is not advisable to mix different engine oils We recommend changing the engine oil when neces sary Mount and tighten filler plug 1 with the O ring ...

Page 225: ...g them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Start the engine and check for tightness Finishing work Check the engine oil level p 215 ...

Page 226: ...r jet directly on to electrical components connectors throttle cables or bearings Maintain a minimum distance between the nozzle of the pressure cleaner and the component Minimum clearance 60 cm 23 6 in Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the applicable regulat...

Page 227: ...er and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the vehicle with water first If the vehicle was operated in road salt clean it with cold water Warm water would enhance the corrosive effects of salt After rinsing the motorcycle with a gentle spray of water allow it to dry thoroughly Remove the closure of the exhaust system Warning Danger of accidents Moisture and d...

Page 228: ...has penetrated to evaporate After the motorcycle has cooled down lubricate all moving parts and pivot points Clean the chain p 109 Treat bare metal except for brake discs and the exhaust sys tem with a corrosion inhibitor Preserving materials for paints metal and rubber p 260 Treat all painted parts with a mild paint care product Perfect finish and high gloss polish for paints p 260 Info Do not po...

Page 229: ...ricate the ignition steering lock Universal oil spray p 260 18 2 Checks and maintenance steps for winter operation Info If you use the motorcycle in winter salt can be expected on the roads You should therefore take precau tions against aggressive road salt After riding on salted roads thoroughly clean the vehicle with cold water and dry it well Warm water enhances the corrosive effects of salt ...

Page 230: ...oving them with cold water and dry them carefully After riding on salted roads thoroughly clean the motorcycle with cold water and dry it well Treat the engine the swingarm and all other bare or zinc plated parts except the brake discs with a wax based corro sion inhibitor Info Corrosion inhibitor must not come in contact with the brake discs as this would greatly reduce the braking force Clean th...

Page 231: ...case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Info If you plan to garage the motorcycle for a longer period perform the following steps or have them per formed Before storing the motorcycle check all parts for function and wear If service repairs or replacements are necessary you s...

Page 232: ...freeze and coolant level p 199 Check tire pressure p 167 Remove the 12 V battery p 171 Charge the 12 V battery p 176 Guideline Storage temperature of the 12 V battery without direct sunlight 0 35 C 32 95 F Store the vehicle in a dry location that is not subject to large fluctuations in temperature Info KTM recommends jacking up the motorcycle Raise the motorcycle with a lift stand p 92 Cover the m...

Page 233: ...annot warm up properly the water vapor produced during combustion condenses and causes valves and the exhaust system to rust 19 2 Preparing for use after storage 401059 01 Remove the motorcycle from the lift stand p 92 Charge the 12 V battery p 176 Install the 12 V battery p 173 Set the clock p 46 Perform checks and maintenance measures when preparing for use p 58 Take a test ride ...

Page 234: ...heck the ground connection Engine turns only if the clutch lever is drawn The vehicle is in gear Shift the transmission to neutral posi tion The vehicle is in gear and the side stand is folded out Shift the transmission to neutral posi tion Engine turns but does not start Operating error Carry out the start procedure p 59 Fuse 3 blown Change the fuses of individual power consumers p 183 The plug i...

Page 235: ...essure Error in the electronic fuel injection Read out the fault memory using the KTM diagnostics tool Engine overheats Too little coolant in cooling sys tem Check the cooling system for leakage Check the coolant level p 202 Radiator fins very dirty Clean radiator fins Foam formation in cooling sys tem Drain the coolant p 204 Fill bleed the cooling system p 205 Buckled or damaged radiator hose Cha...

Page 236: ...nce in wheel speeds of the front and rear wheels Stop the vehicle switch off the igni tion and start it again Malfunction in ABS Read out the ABS fault memory using the KTM diagnostics tool High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary Engine oil level too high Check the engine oil level p 215 Engine oil too thin low viscos ity Change the en...

Page 237: ...the 12 V battery p 176 The 12 V battery is not being charged by the alternator Check the charging voltage Check the open circuit current Combination instrument shows nothing in the display Fuse 1 or 2 blown Change the fuses of individual power consumers p 183 Set the clock p 46 Speedometer in combination instrument not functioning Speedometer wiring harness is damaged or plug in connection is oxid...

Page 238: ...vers exhaust controlled by rocker arm chain drive Valve diameter intake 42 mm 1 65 in Valve diameter exhaust 34 mm 1 34 in Valve play cold Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Exhaust at 20 C 68 F 0 22 0 27 mm 0 0087 0 0106 in Crankshaft bearing 2 roller bearings Conrod bearing Slide bearing Piston pin bearing Piston pin with DLC coating Pistons Forged light alloy Piston rings 1 compr...

Page 239: ...sion claw shifted Transmission ratio First gear 14 35 Second gear 16 28 Third gear 20 27 Fourth gear 21 23 Fifth gear 23 22 Sixth gear 23 20 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V 300 W Spark plug Inside spark plug NGK LKAR9BI 10 Outside spark plug NGK LMAR7DI 10 Spark plug electrode g...

Page 240: ...f ft Oil nozzle for conrod bearing lubri cation M4 0 8 Nm 0 59 lbf ft Locking screw for bearing M5 6 Nm 4 4 lbf ft Loctite 243 Remaining screws engine M5 6 Nm 4 4 lbf ft Screw axial lock of camshaft M5 6 Nm 4 4 lbf ft Loctite 243 Screw clutch spring M5 8 Nm 5 9 lbf ft Screw cover plate for oil return line M5 6 Nm 4 4 lbf ft Screw gear sensor M5 5 Nm 3 7 lbf ft Loctite 243 Screw oil filter cover M5...

Page 241: ...t through hole 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 Screw crankshaft speed sensor M6 10 Nm 7 4 lbf ft Loctite 243 Screw cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw cylinder head M6 10 Nm 7 4 lbf ft Loctite 243 Screw engine case M6 10 Nm 7 4 lbf ft S...

Page 242: ...t 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 pump wheel M6 10 Nm 7 4 lbf ft Loctite 243 Intake channel vacuum connection M6x0 75 2 5 Nm 1 84 lbf ft Loctite 243 Oil jet piston cooling M6x0 75 4 Nm 3 lbf ft Loctite 243 Nut exhaust flange M8 20 Nm 14 8 lbf ft Copper paste Screw plug locking screw M8 15 Nm 11 1 lbf ft Screw rocker arm shaft...

Page 243: ...ted with engine oil Oil line for oil pressure sensor M10x1 10 Nm 7 4 lbf ft Oil pressure sensor M10x1 10 Nm 7 4 lbf ft Screw plug oil channel M10x1 15 Nm 11 1 lbf ft Loctite 243 Screw plug oil channel for oil radiator M10x1 15 Nm 11 1 lbf ft Screw plug water pump drain hole M10x1 15 Nm 11 1 lbf ft Screw unlocking of timing chain tensioner M10x1 10 Nm 7 4 lbf ft Spark plug outside M10x1 11 Nm 8 1 l...

Page 244: ...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 5 120 Nm 88 5 lbf ft Loctite 243 Nut primary gear wheel M20LHx1 5 90 Nm 66 4 lbf ft Loctite 243 Plug oil screen M20x1 5 15 Nm 11 1 lbf ft Plug oil thermostat M24x1 5 15 Nm 11 1 lbf ft Plug timing chain tensioner M24x1 5...

Page 245: ...gine oil 1 70 l 1 8 qt Engine oil SAE 10W 50 p 257 21 3 2 Coolant Coolant 1 20 l 1 27 qt Coolant p 256 21 3 3 Fuel A00420 10 Please observe the labels on EU fuel pumps Total fuel tank capacity approx 13 5 l 3 57 US gal Super unleaded ROZ 95 RON 95 PON 91 p 258 ...

Page 246: ...r WP SuspensionXPLOR 5746 Suspension travel front 250 mm 9 84 in rear 250 mm 9 84 in Brake system front Disc brake with dual piston brake caliper floating rear Disc brake with single piston brake caliper floating Brake discs diameter front 300 mm 11 81 in rear 240 mm 9 45 in Brake discs wear limit front 4 5 mm 0 177 in rear 4 5 mm 0 177 in Tire pressure road solo front 1 8 bar 26 psi ...

Page 247: ... 22 psi Secondary drive ratio 15 46 Chain 5 8 x 1 4 X ring Steering head angle 62 3 Wheelbase 1 504 15 mm 59 21 0 59 in Seat height unloaded 910 mm 35 83 in Ground clearance unloaded 270 mm 10 63 in Weight without fuel approx 149 kg 328 lb 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 ...

Page 248: ...ent battery CR 2430 Battery voltage 3 V Fuse 58011109130 30 A Fuse 58011109125 25 A Fuse 58011109115 15 A Fuse 75011088015 15 A Fuse 75011088010 10 A Headlight H4 socket P43t 12 V 60 55 W Position light W5W socket W2 1x9 5d 12 V 5 W Combination instrument lighting and indicator lamps LED Turn signal LED Brake tail light LED License plate lamp LED ...

Page 249: ...sible series production tires Additional information is available in the Service section under http www ktm com 21 7 Fork Fork article number 14 18 8S 10 Fork WP SuspensionXPLOR 5448 Compression damping Comfort 10 clicks Standard 15 clicks Sport 20 clicks Full payload 20 clicks Rebound damping Comfort 10 clicks Standard 15 clicks Sport 20 clicks Full payload 20 clicks ...

Page 250: ... 640 ml 21 64 fl oz Fork oil SAE 4 48601166S1 p 258 21 8 Shock absorber Shock absorber article number 15 18 7S 10 Shock absorber WP SuspensionXPLOR 5746 High speed compression damping Comfort 2 5 turns Standard 2 turns Sport 1 turn Full payload 1 turn Low speed compression damping Comfort 25 clicks Standard 20 clicks Sport 10 clicks Full payload 10 clicks Rebound damping ...

Page 251: ... ft Screw combination switch EJOT PT K50x18 T20 2 Nm 1 5 lbf ft Screw side cover on spoiler EJOT 1 Nm 0 7 lbf ft Screw side stand switch EJOT 2 Nm 1 5 lbf ft Fitting side stand switch M4 2 Nm 1 5 lbf ft Spoke nipple front wheel M4 5 4 Nm 3 lbf ft Remaining nuts chassis M5 4 Nm 3 lbf ft Remaining screws chassis M5 4 Nm 3 lbf ft Screw brake line holder on swingarm M5 4 Nm 3 lbf ft Screw cable on sta...

Page 252: ... 3 lbf ft Screw fuel tank closure flange M5 2 5 Nm 1 84 lbf ft Screw headlight mask M5 5 Nm 3 7 lbf ft Screw pressure regulator M5 4 Nm 3 lbf ft Screw radiator guard M5 4 Nm 3 lbf ft Screw throttle grip M5 3 5 Nm 2 58 lbf ft Spoke nipple rear wheel M5 4 Nm 3 lbf ft Remaining nuts chassis M6 10 Nm 7 4 lbf ft Remaining screws on fuel tank M6 5 Nm 3 7 lbf ft Remaining screws chassis M6 10 Nm 7 4 lbf ...

Page 253: ...oir for rear brake M6 5 Nm 3 7 lbf ft Screw chain guard M6 2 Nm 1 5 lbf ft Loctite 243 Screw chain guide M6 8 Nm 5 9 lbf ft Screw chain sliding guard M6 8 Nm 5 9 lbf ft Loctite 243 Screw clutch assembly M6 5 Nm 3 7 lbf ft Screw front brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw ignition lock M6 10 Nm 7 4 lbf ft Loctite 243 Screw license plate holder bot tom M6 8 Nm 5 9 lbf ft Screw license pl...

Page 254: ...Screw seat lock M6 5 Nm 3 7 lbf ft Screw side cover M6 5 Nm 3 7 lbf ft Screw upper part of the air filter box M6 2 Nm 1 5 lbf ft Screw upper radiator bracket M6 10 Nm 7 4 lbf ft Screw voltage regulator M6 8 Nm 5 9 lbf ft Screw wheel speed sensor M6 6 Nm 4 4 lbf ft Nut manifold on cylinder head M8 20 Nm 14 8 lbf ft Copper paste Nut rear sprocket screw M8 35 Nm 25 8 lbf ft Loctite 2701 Remaining nut...

Page 255: ...footrest bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw fuel tank bracket M8 15 Nm 11 1 lbf ft Screw fuel tank bottom M8 25 Nm 18 4 lbf ft Loctite 243 Screw fuel tank top M8 25 Nm 18 4 lbf ft Loctite 243 Screw grab handle M8 10 Nm 7 4 lbf ft Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw heel protector M8x12 5 Nm 3 7 lbf ft Loctite 243 Screw main silencer holder M8 25 Nm 18 4 lbf ft Screw main s...

Page 256: ...ning nuts chassis M10 45 Nm 33 2 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 engine bearer on frame M10 45 Nm 33 2 lbf ft Screw handlebar support M10 45 Nm 33 2 lbf ft Loctite 243 Screw side stand M10 35 Nm 25 8 lbf ft Loctite 243 Screw top shock absorber M10 45 Nm 33 2 lbf ft Loctite 243 Banjo bolt brake line M10x1 25 N...

Page 257: ...er arm M14x1 5 100 Nm 73 8 lbf ft Screw radiator temperature sensor M18 20 Nm 14 8 lbf ft Screw bottom steering head M20x1 5 60 Nm 44 3 lbf ft Loctite 243 Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Screw front wheel spindle M24x1 5 45 Nm 33 2 lbf ft Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft ...

Page 258: ... 1 Coolant Guideline Only use high grade silicate free coolant with corrosion inhibitor additive for aluminum motors Low grade and unsuitable antifreeze causes corrosion deposits and frothing Do not use pure water as only coolant is able to meet the requirements needed in terms of corrosion protec tion and lubrication properties Only use coolant that complies with the requirements stated see speci...

Page 259: ... for antifreeze protection dilution and miscibility compatibility with other coolants Recommended supplier MOTOREX COOLANT M3 0 Engine oil SAE 10W 50 Standard classification JASO T903 MA2 p 261 SAE p 261 SAE 10W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties Fully synthetic engine oil Reco...

Page 260: ...E 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding properties Super unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe ...

Page 261: ...TOREX Chain Clean Fuel additive Recommended supplier MOTOREX Fuel Stabilizer Long life grease Recommended supplier MOTOREX Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX Moto Clean Off road chain spray Recommended supplier MOTOREX Chainlube Offroad ...

Page 262: ...OTOREX Moto Shine Preserving materials for paints metal and rubber Recommended supplier MOTOREX Moto Protect Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Universal oil spray Recommended supplier MOTOREX Joker 440 Synthetic ...

Page 263: ...ice intervals are demanded for automobile engines the focus for motorcycle engines is on high performance at high engine speeds In most motorcycle engines the transmission and clutch are lubricated with the same oil The JASO T903 MA2 standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils accordin...

Page 264: ... influence of lateral forces MTC Motorcycle Traction Control Auxiliary function of the motor control that reduces engine torque with spinning rear wheel OBD On board diagnosis Vehicle system which monitors the specified parame ters of the vehicle electronics Quickshifter Engine electronics function for shifting up and down without clutch actuation ...

Page 265: ...LIST OF ABBREVIATIONS 26 263 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 266: ...s in the process and switch off the engine 27 2 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention Active driving aids are also represented by yellow or orange symbols ABS warning lamp lights up flashes yellow If the ABS warning lamp lights up the ABS is not active The ABS warning lamp also lights up if an error is detected Contact an ...

Page 267: ...n error as been detected Contact an authorized KTM workshop The TC indicator lamp flashes if the MTC actively engages 27 3 Green and blue symbols Green and blue symbols reflect information The high beam indicator lamp lights up blue The high beam is switched on The idle indicator lamp lights up green The transmission is in neutral Turn signal indicator lamp flashes green The turn signal is switche...

Page 268: ...stem 126 Applying the brakes 72 Auxiliary substances 17 B Brake discs checking 130 Brake fluid front brake adding 132 of rear brake adding 145 Brake fluid level front brake checking 131 rear brake checking 144 Brake linings front brake changing 136 front brake checking 135 of rear brake changing 148 rear brake checking 147 Brakes 72 C Capacity coolant 209 243 engine oil 221 243 fuel 79 243 Chain c...

Page 269: ...combination instrument battery changing 193 kilometers or miles setting 45 messages 44 overview 43 service display setting 47 Coolant antifreeze and coolant level checking 199 changing 207 draining 204 level checking 202 Cooling system 198 filling bleeding 205 Customer service 18 D Diagnostics connector 197 Driving mode changing 211 E Electric starter button 31 Emergency OFF switch 30 Engine runni...

Page 270: ...ebound adjusting 86 Fork part number 26 Fork protector installing 95 removing 95 Front fender installing 106 removing 105 Front wheel installing 155 removing 153 Fuel tank filler cap closing 43 opening 41 Fuel oils etc 17 Fuse individual power consumers changing 183 G Grab handles 37 H Hand brake lever 27 basic position adjusting 129 Headlight range adjusting 193 setting checking 192 Headlight mas...

Page 271: ...and raising with 92 removing from lift stand 92 Motorcycle traction control 71 MTC 71 O Oil filter changing 216 Oil screens cleaning 216 Overview of indicator lamps 35 Owner s Manual 16 P Parking 74 Passenger foot pegs 38 Position light lamp changing 190 Preparing for use advice on preparing for first use 52 after storage 231 checks and maintenance measures when preparing for use 58 Protective clo...

Page 272: ...ever 38 basic position adjusting 214 basic position checking 213 Shifting 63 Shock absorber 84 compression damping general 87 high speed compression damping adjusting 89 low speed compression damping adjusting 87 rebound damping adjusting 90 Shock absorber article number 26 Side cover mounting 104 removing 103 Side stand 40 Spare parts 17 Spoke tension checking 169 Starting 59 Steering head bearin...

Page 273: ...ndition checking 165 Tire pressure checking 167 Tire repair spray using 170 Tool set removing 100 storing 101 Traction control adjusting 212 Transport 76 Troubleshooting 232 235 Turn signal switch 29 Type label 24 U USB USB socket 196 USB socket 196 Use definition 11 V Vehicle identification number 24 View of vehicle front left 20 rear right 22 W Winter operation checks and maintenance steps 227 W...

Page 274: ... 3213909en 3213909en 01 2019 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KISKA KTM ...

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KTM 690 Enduro R 2019, Owner'S Manual

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