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KTM 690 Enduro R AUS, Owner'S Manual, Page: 145 / 190

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KTM 690 Enduro R AUS Owner'S Manual Download Page 145

SERVICE WORK ON THE ENGINE

143

Warning

Environmental hazard

 

Hazardous substances cause environmental damage.

–

Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

–

Place a suitable container under the engine.

100202-10

–

Remove screws

. Remove the oil filter cover

with the O-ring.

–

Pull oil filter

out of the oil filter housing.

Circlip pliers reverse (51012011000)

100203-10

–

Remove screws

. Remove oil filter

with the O-ring.

–

Pull oil filter

out of the oil filter housing.

Circlip pliers reverse (51012011000)

–

Completely drain the engine oil.

–

Thoroughly clean the parts and sealing area.

Summary of Contents for 690 Enduro R AUS

Page 1: ...OWNER S MANUAL 2011 690 Enduro R EU 690 Enduro R AUS UK Art no 3211653en...

Page 2: ......

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

Page 4: ...s is permitted only with the express written permission of the copyright owner ISO 9001 12 100 6061 According to the international quality management standard ISO 9001 KTM uses quality assurance proce...

Page 5: ...rument display 25 Combination instrument speedometer 26 Setting kilometers or miles 26 Combination instrument time 27 Setting the clock 27 Combination instrument display ODO 28 Combination instrument...

Page 6: ...ing the play of the steering head bearing x 69 Removing the seat 70 Mounting the seat 71 Removing the air filter x 71 Installing the air filter x 72 Checking the chain for dirt 73 Cleaning the chain 7...

Page 7: ...x 134 Filling the cooling system x 135 TUNING THE ENGINE 137 Checking the play in the throttle cable 137 Adjusting the play in the throttle cable x 138 Adjusting the engine characteristic 138 SERVICE...

Page 8: ...TABLE OF CONTENTS 6 SUBSTANCES 176 AUXILIARY SUBSTANCES 180 STANDARDS 182 INDEX 183...

Page 9: ...chnical understanding In the interest of your own safety have these jobs performed in an authorized KTM workshop There your motorcycle will be serviced opti mally by specially trained experts using th...

Page 10: ...ch as very muddy or wet roads can lead to above average wear of components such as the transmission train or the brakes For this reason it may be necessary to service or replace worn parts before the...

Page 11: ...mounter 59029019000 During assembly non reusable parts e g self locking screws and nuts seals and seal rings O rings pins lock washers must be replaced by new parts If a thread lock e g Loctite is use...

Page 12: ...conflicts with other persons But if you use your motorcycle responsibly you can ensure that such problems and conflicts do not have to occur To protect the future of motorcycle sport make sure that yo...

Page 13: ...the appropriate measures are not taken Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken Owner s manual It is important that you read this ow...

Page 14: ...VIEW OF VEHICLE 12 3 1 View of vehicle front left example 800087 10...

Page 15: ...VIEW OF VEHICLE 13 1 Hand brake lever p 19 2 Clutch lever p 19 3 Handrails p 33 4 Filler cap 5 Seat 6 Engine number p 17 7 Shift lever p 34 8 Side stand p 35 9 Footrest 10 Seat release p 32...

Page 16: ...VIEW OF VEHICLE 14 3 2 View of vehicle rear right example 800086 10...

Page 17: ...rn signal switch p 21 3 Horn button p 21 4 Combination instrument p 23 5 Emergency OFF switch p 22 5 Electric starter button p 22 6 Throttle grip p 20 7 Chassis number p 16 8 Passenger footrests p 33...

Page 18: ...ERIAL NUMBERS 16 4 1 Chassis number 101045 10 The chassis number is stamped on the steering head on the right 4 2 Type label 101046 10 Type label is located on the upper right frame tube below the sea...

Page 19: ...The engine number is stamped on the left side of the engine under the engine sprocket 4 4 Key number 100179 10 The key number can be found on the KEYCODECARD Info You need the key number to order a s...

Page 20: ...RS 18 4 5 Fork part number 101047 10 The fork part number is stamped on the inner side of the fork stub 4 6 Shock absorber part number 101048 10 The shock absorber part number is on the left of the sh...

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

Page 22: ...t switch 100222 10 The light switch is fitted on the left side of the handlebar Possible states Low beam on Light switch is turned downwards In this position the low beam and tail light are switched o...

Page 23: ...the central position after use Turn signal light right on Turn signal switch pressed to the right The turn signal switch returns automatically to the central position after use To switch off the turn...

Page 24: ...ed 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 5 8 Electric starter button 100226 10 The...

Page 25: ...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...

Page 26: ...The indicator lamps offer additional information about the operating state of the motorcy cle Possible states The turn signal indicator light flashes green simultaneously with the turn signals Turn s...

Page 27: ...t display 800083 13 When you switch on the ignition all display segments light up for a second as a function test 800083 14 LEnGth Following the display function test the wheel circumference LEnGth is...

Page 28: ...he speed is shown in kilometers per hour km h or in miles per hour mph 5 15 Setting kilometers or miles Info If you change the unit the value is retained and converted accordingly Making the setting a...

Page 29: ...ton pressed until the display mode changes from km h to mph or from mph to km h Guideline Activation duration of M button 10 s 5 16 Combination instrument time 800083 17 The time is shown in area of t...

Page 30: ...ed simultaneously The time is set 5 18 Combination instrument display ODO 800083 18 In the Odo display mode the total distance traveled is shown in kilometers or miles Info This value is retained even...

Page 31: ...ing TRIP 2 Info The TRIP 2 trip counter runs constantly and counts up to 999 9 The trip counter can be used to measure the distance covered during trips or between two refueling stops After the value...

Page 32: ...o the Trip F display the fuel warning light switches on 5 22 Combination instrument coolant temperature indicator 800085 10 The temperature display consists of 8 bars The more bars that light up the h...

Page 33: ...ng Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc t...

Page 34: ...5 24 Closing filler cap 101070 01 Put the filler cap back on and turn the ignition key 90 clockwise Remove the ignition key and fold down the cover 5 25 Seat release 101049 10 The seat can be released...

Page 35: ...ave a passenger the passenger can hold on the handrails during the journey 5 27 Passenger footrests 100231 01 The passenger footrests can be folded up and down Possible states Passenger footrests fold...

Page 36: ...5 28 Shift lever 100215 10 The shift lever is mounted on the left side of the engine 100212 10 The gear positions can be seen in the photograph The neutral or idle position is between the first and s...

Page 37: ...stand is used for parking the motorcycle Info The side stand must be folded up during motorcycle use The side stand is coupled with the safety electric starter system see the riding instructions Poss...

Page 38: ...ashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control ov...

Page 39: ...first trip read the entire operating instructions carefully Get to know the controls Adjust the basic position of clutch lever p 84 Adjust the free travel of the hand brake lever p 87 Adjust the basic...

Page 40: ...d helmet baggage Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and or tank rucksack Mount and secure suitcase and tank rucksack according to the m...

Page 41: ...table handling characteristics due to slipped baggage Check the way your baggage is fixed regularly Warning Danger of burns A hot exhaust system can burn baggage Fasten your baggage in such a way that...

Page 42: ...ke fluid level p 97 Check the front brake linings p 91 Check the rear brake linings p 100 Check the brake system function Check the coolant level p 132 Check the chain for dirt p 73 Check the chain te...

Page 43: ...d safety equipment may be damaged Never operate the vehicle with a discharged battery or without a battery Note Engine failure High engine speeds in cold engines have a negative effect on the service...

Page 44: ...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 as far as it wi...

Page 45: ...passengers in your country Warning Danger of accidents Danger of accidents caused by dangerous driving Comply with traffic regulations and ride defensively and foresightedly to detect sources of dang...

Page 46: ...as usual before putting it into operation Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never ride the vehicle without an air filter since dust and...

Page 47: ...nsid erably lower Accelerate only up to a speed suitable for the road surface and weather conditions When traveling in bends do not shift and accelerate very carefully To shift down brake if necessary...

Page 48: ...ing and braking gently Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake Check the brake system and do not continue riding Your authorized K...

Page 49: ...t do not overstress the engine In this way you have to brake far less and the brakes do not overheat 7 6 Stopping parking Warning Risk of misappropriation Usage by unauthorized persons Never leave the...

Page 50: ...o flow to most power consumers and the battery will discharge You should therefore always switch off the engine with the ignition key the emergency OFF switch is intended for emergencies only Park the...

Page 51: ...e Premature clogging of the fuel filter In some countries and regions the available fuel quality and cleanliness may not be sufficient This will result in problems with the fuel system Your authorized...

Page 52: ...Total fuel tank capacity approx 12 l 3 2 US gal Super unleaded ROZ 95 RON 95 PON 91 p 179 Close the filler cap p 32 800083 25 Press the S button for two seconds The fuel level warning lamp switches of...

Page 53: ...d leakage Check the rear brake fluid level p 97 Check the free travel of the foot brake lever p 96 Lubricate the linkage of the rear wheel suspension x Check that the shock absorber and fork are leak...

Page 54: ...routing x Check the antifreeze and coolant level p 130 Check the cables for damage and routing without sharp bends x Check that the throttle cables are undamaged routed without sharp bends and set cor...

Page 55: ...for roadworthiness and take a test ride Read out the fault memory using the KTM diagnostics tool after a test ride x Make the service entry in KTM DEALER NET and in the service record x K10N Once aft...

Page 56: ...sis of your own personal chassis adaptation Do not change the adjustments at random or by more than 40 since otherwise the riding characteristics could deteriorate particularly at high speeds 9 2 Adju...

Page 57: ...to reduce damping 9 3 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork rebound behavior 101052 10 Turn adjusting screws clockwise until they stop Info...

Page 58: ...he landing after a jump the rear wheel suspension compresses more quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses more...

Page 59: ...he shock absorber type Guideline Compression damping low speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise...

Page 60: ...ock absorber type Guideline Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce d...

Page 61: ...Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 9 8 Measuring the unloaded rear wheel sag Raise the motorcycl...

Page 62: ...upright with the aid of an assistant Measure the distance between the rear axle and the fixed point again Note down the value as dimension Info The static sag is the difference between measurements a...

Page 63: ...on now measures the distance between the rear axle and a fixed point Note down the value as dimension Info The riding sag is the difference between measurements and Check the riding sag Riding sag 70...

Page 64: ...Loosen locking ring Turn adjusting ring until the spring is no longer under tension Hook wrench T106S Measure the overall spring length without a load Tension the spring by turning the adjusting ring...

Page 65: ...nstalled in the position most comfortable for the rider 9 13 Adjusting handlebar position x 0 0 2 2 0 0 1 1 0 0 2 2 1 1 B00375 10 Remove the four screws Remove the handlebar clamp Remove the handlebar...

Page 66: ...HASSIS 64 Position the handlebar Info Make sure cables and wiring are positioned correctly Position the handlebar clamp Fit and evenly tighten the four screws Guideline Screw handlebar clamp M8 20 Nm...

Page 67: ...e the motorcycle using the underride guard under the motorcycle The wheels must no longer touch the ground Secure the motorcycle against falling over 10 2 Removing the motorcycle from the lift stand N...

Page 68: ...the motorcycle with the lift stand p 65 Loosen the fork protection p 67 100293 10 Push dust boot of both fork legs downwards Info The dust boots should remove dust and coarse dirt particles from the...

Page 69: ...ck into their normal position Remove excess oil Position the fork protection p 68 Remove the motorcycle from the lift stand p 65 10 5 Loosening the fork protection 101055 10 Remove screws and take off...

Page 70: ...right fork leg Mount and tighten the screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 10 7 Checking the steering head bearing play Warning Danger of accidents Unstable vehicle handling fr...

Page 71: ...ring range No resting locations should be noticeable If click positions are noticeable Adjust the play of the steering head bearing x p 69 Check the steering head bearing and change if necessary Remov...

Page 72: ...ew steering stem M8 20 Nm 14 8 lbf ft Loctite 243 Check the steering head bearing play p 68 Remove the motorcycle from the lift stand p 65 10 9 Removing the seat 101049 10 Pull on strap and raise the...

Page 73: ...ard and at the same time push it forward Push locking pin into lock housing and push the back of the seat down until the locking pin locks in place with an audible click Finally check that the seat is...

Page 74: ...he engine and result in increased wear Remove air filter 10 12 Installing the air filter x 100287 10 Clean the air filter box Mount air filter Info The air filter must lie flush against the air filter...

Page 75: ...5 lbf ft Mount the seat p 71 10 13 Checking the chain for dirt 400678 01 Check the chain for heavy soiling If the chain is very dirty Clean the chain p 73 10 14 Cleaning the chain Warning Danger of a...

Page 76: ...tal hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info The service life of the c...

Page 77: ...hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check the chain tension and correct if necessary 100249 10 Lean the m...

Page 78: ...sprocket rear sprocket bearings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can br...

Page 79: ...marks The rear wheel is then correctly aligned Info The upper chain section must be taut Chain wear is not always even so you should check this setting at different chain positions Tighten nuts Make s...

Page 80: ...the motorcycle with the lift stand p 65 100132 10 Shift gear to neutral Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Replace the rear sprocket...

Page 81: ...in links in the lower chain section Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance at the longest chain section 272 mm 10 71 in...

Page 82: ...edge of the chain pins is in line with or below the chain sliding guard Replace the chain sliding guard x Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tighte...

Page 83: ...ge the chain sliding piece x Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 l...

Page 84: ...CHASSIS 82 101068 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the chain guide Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Remove the motorcycle from...

Page 85: ...ion Number of teeth 44 teeth Insert nut in hole Position the chain guide Mount and tighten screws and Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Condition Number of teeth 45 teeth Insert n...

Page 86: ...only and do not apply any force Do not make any adjustments while riding 100282 10 Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw When adjusting the clutch l...

Page 87: ...olant does not meet specifications Correct the fluid level of the hydraulic clutch Hydraulic fluid 15 p 178 Position the cover with the membrane Mount and tighten the screws 10 21 Removing the engine...

Page 88: ...N THE CHASSIS 86 10 22 Installing the engine guard 100199 10 Slide the engine guard into holders at the rear Position the engine guard Mount and tighten screws Guideline Remaining screws chassis M6 10...

Page 89: ...t free travel on hand brake lever according to specifications 100251 10 Push the hand brake to the handlebar and check free travel Free travel of hand brake lever 3 mm 0 12 in If the free travel does...

Page 90: ...g 11 3 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc s Change the worn brake disc s without delay Your authorized KTM workshop will be glad to...

Page 91: ...ystem or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking effect caused by old bra...

Page 92: ...he eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and re...

Page 93: ...fluid immediately with water 11 6 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your autho...

Page 94: ...rs must be carried out professionally Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and ke...

Page 95: ...ly from the original KTM brake lin ings If brake linings are used that differ from the originals there is no guarantee that they comply with the original license The vehicle no longer corresponds to t...

Page 96: ...d in order to push back the brake pis tons Make sure that no brake fluid escapes from the brake fluid reservoir If it does clean it up Info Make sure when pushing back the brake pistons that you do no...

Page 97: ...the cotter pin Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point 100254 12 Adjust the brake fluid level to level Guidelin...

Page 98: ...ree travel 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 ac...

Page 99: ...brake lever has the necessary free travel Hold screws in place and tighten the nuts Guideline Nut foot brake cylinder screw M6 10 Nm 7 4 lbf ft Check the free travel of the foot brake lever p 96 Tight...

Page 100: ...brake fluid x Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check th...

Page 101: ...s stipulated in 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...

Page 102: ...e braking effect is greatly reduced and the brake discs are rendered unserviceable Check the brake linings regularly 100260 10 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 04...

Page 103: ...brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents Reduced braking efficiency due to use of non approved brake linings Brake linings availa...

Page 104: ...nd the vehicle upright Remove screw cap with membrane Press the brake caliper onto the brake disc by hand in order to push back the brake piston Make sure that no brake fluid escapes from the brake fl...

Page 105: ...brake linings insert the bolt and mount the cotter pin Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Add brake fluid...

Page 106: ...12 1 Removing the front wheel x Raise the motorcycle with the lift stand p 65 101060 01 Press the brake caliper by hand on to the brake disc in order to press back the brake pistons 101061 10 Remove s...

Page 107: ...front wheel is removed Always lay the wheel down in such a way that the brake disc is not damaged 800080 10 Remove distance bushings 12 2 Installing the front wheel x Warning Danger of accidents Reduc...

Page 108: ...11 Lift the front wheel into the fork position it and insert the wheel spindle Mount and tighten screw Guideline Screw front wheel spindle M24x1 5 40 Nm 29 5 lbf ft Activate the hand brake lever multi...

Page 109: ...ster Holding the rear wheel withdraw the wheel spindle 100268 01 Push the rear wheel forwards as far as possible and take the chain off the rear sprocket Warning Danger of accidents Reduced braking ef...

Page 110: ...e foot brake until the pressure point is reached Check the rear hub rubber dampers x p 109 100269 10 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Replace the whe...

Page 111: ...in the same position Tighten nut Guideline Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and ther...

Page 112: ...l spindle in the hub To check play hold the rear wheel tight and try to rotate the rear sprocket Info Measure the play on the outside of the rear sprocket Play in rubber dampers rear wheel 5 mm 0 2 in...

Page 113: ...oth rolling surface and therefore cannot provide full road grip The entire rolling surface must be rough ened in the first 200 kilometers 124 3 miles by moderate riding at alternating angles The full...

Page 114: ...s that the tires are changed regardless of the actual wear at the latest after five years If a tire is more than five years old Change the tires 12 7 Checking the tire air pressure Info Low tire air p...

Page 115: ...hecking the spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that the spoke tension is correct Your authorized KTM workshop will be glad to help Info A...

Page 116: ...of the tone is a function of the spoke length and spoke diameter If you hear different tone frequencies from individual spokes of the same length and thickness this is an indication of different spok...

Page 117: ...es with water for at least 15 minutes and consult a physician Switch off all power consumers and switch off the engine Remove the seat p 70 100277 10 Disconnect the negative minus cable of the battery...

Page 118: ...Mount the seat p 71 Set the clock p 27 13 3 Recharging the battery x Warning Risk of injury Battery acid and battery gases cause serious cauterization Keep batteries out of the reach of children Wear...

Page 119: ...ses power steadily The charge state and the type of charge are very important for the service life of the battery Rapid recharging with a high charging current shortens the battery s service life If t...

Page 120: ...ve lid Charge the battery with a maximum of 10 of the capacity specified on the bat tery housing Switch off and disconnect the charger after charging Guideline The charge current charge voltage and ch...

Page 121: ...ers and switch off the engine Remove the seat p 70 600604 10 Remove protection covers 600605 10 Remove a defective main fuse with needle nose pliers Install a new main fuse Fuse 58011109130 p 168 Info...

Page 122: ...uses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat Switch off all power consumers and switch off the engine Remove the se...

Page 123: ...tail light license plate lamp Fuse 8 10 A for supplementary equipment accessories connected with ignition switch Fuse 9 10 A for accessories permanent positive Fuse 10 not used Fuse SPARE 10 A 15 A s...

Page 124: ...e fuse in the fuse box for future use if needed Check the function of power consumers Close the fuse box cover Mount the seat p 71 13 6 Removing the headlight mask with the headlight Switch off all po...

Page 125: ...101063 10 Remove screw and take off the clamp Release rubber band Slide the headlight mask upward and tilt it forward 800102 10 Disconnect the electrical plug in connection and remove the headlight ma...

Page 126: ...ELECTRICAL SYSTEM 124 13 7 Installing the headlight mask with the headlight 800102 11 Connect the electrical plug in connection...

Page 127: ...on the brake line and wiring harness Position the clamp and mount and tighten screw 13 8 Changing the headlight bulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to...

Page 128: ...rt the holder into the headlight housing and fix it by turning it approx 30 clock wise Replace the rubber cap Attach the connector Install the headlight mask with the headlight p 124 13 9 Changing the...

Page 129: ...rate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting 100301 10 Remove the screw on the rear of the turn signal housing Tilt headlamp diffuse...

Page 130: ...at the height of the center of the low beam headlight Make another mark at a distance under the first mark Guideline Distance 5 cm 2 in Position the vehicle vertically at a distance in front of the w...

Page 131: ...064 10 Loosen screw Adjust the light range by swiveling the headlight Guideline For a motorcycle with rider the light dark boundary must be exactly on the lower mark made in Checking headlight adjustm...

Page 132: ...without causing any malfunctions 125 C 257 F 400407 10 Cooling takes place by means of the air stream and a radiator fan which is controlled by a thermoswitch The lower the speed the less the cooling...

Page 133: ...the reach of children Condition Engine is cold 101065 10 Stand the motorcycle on its side stand on a horizontal surface Remove the cap of the compensating tank Check antifreeze of coolant 25 45 C 13...

Page 134: ...cifications Correct the coolant level and find out the cause of the loss Alternative 1 Coolant p 176 Alternative 2 Coolant mixed ready to use p 176 Mount the radiator cap 14 3 Checking the coolant lev...

Page 135: ...dren Condition Engine is cold 101065 10 Stand the motorcycle on its side stand on a horizontal surface Check the coolant level in the compensating tank The coolant level must be within the range shown...

Page 136: ...nd a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap a...

Page 137: ...ffected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolant out of the reach of childr...

Page 138: ...or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engi...

Page 139: ...y in the throttle cable x p 138 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is su...

Page 140: ...en counter nut Set the play in the throttle cable by turning the adjusting screw Guideline Throttle cable play 3 5 mm 0 12 0 2 in Tighten counter nut 15 3 Adjusting the engine characteristic Switch of...

Page 141: ...with extremely direct responsiveness Set the Map Select switch to Standard Set the adjusting wheel to position 3 4 5 6 7 8 or 9 Standard homologated performance with balanced responsiveness Set the M...

Page 142: ...s at operating temperature Stand the motorcycle upright on a horizontal surface 100210 10 Check the engine oil level Info After switching off the engine wait one minute before checking the level The e...

Page 143: ...e oil x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with luk...

Page 144: ...the oil drain plug with a magnet Mount the oil drain plug with the magnet and seal ring and tighten it Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft 16 4 Removing the oil filter x War...

Page 145: ...tions Place a suitable container under the engine 100202 10 Remove screws Remove the oil filter cover with the O ring Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000 1...

Page 146: ...otective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners...

Page 147: ...oroughly clean the parts and sealing area 100207 10 Position oil screen with the O rings Mount and tighten screw plug with the O ring Guideline Plug oil screen M20x1 5 15 Nm 11 1 lbf ft 100208 10 Posi...

Page 148: ...Screw oil filter cover M5 6 Nm 4 4 lbf ft 16 7 Filling up with engine oil x Info Too little engine oil or poor quality engine oil results in premature wear to the engine 100209 10 Remove filler plug w...

Page 149: ...ck that it is oil tight Install the engine guard p 86 Check the engine oil level p 140 16 8 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the eng...

Page 150: ...m may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhau...

Page 151: ...stipulated in applicable regulations Info If you clean the motorcycle regularly its value and appearance will be maintained over a long period Avoid direct sunshine on the motorcycle during cleaning...

Page 152: ...allow any water that has penetrated to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 73 Treat bare metal parts except for brake discs and exh...

Page 153: ...d water Warm water enhances the corrosive effects of salt 401060 01 Clean the motorcycle p 149 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with a wax based...

Page 154: ...you can fill up with fresh fuel when you put the motorcycle back into operation Clean the motorcycle p 149 Change the engine oil and filter clean the oil screens x p 141 Check the antifreeze and coola...

Page 155: ...annot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 18 2 Preparing for use after storage 401059 01 Remove the motorcycle from the l...

Page 156: ...start Operating error Carry out the start procedure p 41 Fuse 4 blown Change the fuses of individual power consumers p 120 Coupling of fuel hose connection not connected Reconnect coupling of fuel ho...

Page 157: ...flashes Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x Engine dies during the journey Lack of fuel Refuel p 48 Fuse 1 2 or 4 blown Change the fuses of ind...

Page 158: ...parked Recharge the battery x p 116 Battery is not charged by alternator Check the charging voltage x Check the quiescent current x Combination instrument shows nothing in the display Fuse 1 blown Ch...

Page 159: ...warning lamp MIL flashes briefly 8x Error level condition Accelerator position sensor input signal too low Accelerator position sensor input signal too high Blink code FI of warning lamp MIL 09 FI wa...

Page 160: ...re sensor input signal too low Ambient air pressure sensor input signal too high Blink code FI of warning lamp MIL 15 FI warning lamp MIL flashes 1x long 5x short Error level condition Rollover sensor...

Page 161: ...MIL flashes 3x long 7x short Error level condition Ignition coil cylinder 1 circuit fault Blink code FI of warning lamp MIL 41 FI warning lamp MIL flashes 4x long 1x short Error level condition Fuel p...

Page 162: ...short Error level condition EPT motor drive relay permission signal fault Blink code FI of warning lamp MIL 60 FI warning lamp MIL flashes 6x long Error level condition Motor drive circuit fault Blin...

Page 163: ...BLINK CODE 161 Blink code FI of warning lamp MIL 92 FI warning lamp MIL flashes 9x long 2x short Error level condition Motor drive voltage internal circuit fault...

Page 164: ...r exhaust 34 mm 1 34 in Valve play cold 0 07 0 13 mm 0 0028 0 0051 in Crankshaft bearing 2 roller bearings Conrod bearing Needle bearing Piston pin bearing Bronze bush Pistons Forged light alloy Pisto...

Page 165: ...rk plug NGK LKAR 8AI 9 Spark plug electrode gap 0 9 mm 0 035 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid Electric starter automatic decompressor 21 1 Capacity...

Page 166: ...l filter cover M5 6 Nm 4 4 lbf ft Screw oil pump cover M5 6 Nm 4 4 lbf ft Loctite 243 Plug vacuum connection M6 10 Nm 7 4 lbf ft Loctite 243 Screw in alternator cover M6 10 Nm 7 4 lbf ft Screw alterna...

Page 167: ...rail M6 10 Nm 7 4 lbf ft Loctite 243 Screw timing chain tensioning rail M6 10 Nm 7 4 lbf ft Loctite 243 Screw valve cover M6 10 Nm 7 4 lbf ft Screw water pump cover M6 10 Nm 7 4 lbf ft Screw water pu...

Page 168: ...net M12x1 5 20 Nm 14 8 lbf ft Oil pressure regulator valve plug M12x1 5 20 Nm 14 8 lbf ft Plug oil bore M14x1 5 15 Nm 11 1 lbf ft Loctite 243 Engine case stud M16x1 5 25 Nm 18 4 lbf ft Loctite 243 Rot...

Page 169: ...c 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...

Page 170: ...rmissible front axle load 150 kg 331 lb Maximum permissible rear axle load 200 kg 441 lb Maximum permissible overall weight 350 kg 772 lb Battery YTZ10S Battery voltage 12 V Nominal capacity 8 6 Ah ma...

Page 171: ...n 90 90 21 M C 54S M S TT Continental TKC 80 140 80 18 M C 70R M S TT Continental TKC 80 To max 160 km h 99 4 mph Additional information is available in the Service section under http www ktm com 23 3...

Page 172: ...Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring length with preload spacer s 495 mm 19 49 in Spring rate Soft 5 0 N mm 28 6 lb in Medium standard 5 2...

Page 173: ...payload 1 turn Compression damping low speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full paylo...

Page 174: ...TECHNICAL DATA SHOCK ABSORBER 172 Riding sag 70 80 mm 2 76 3 15 in Fitted length 405 mm 15 94 in Shock absorber oil p 178 SAE 2 5...

Page 175: ...eadlight mask M5 5 Nm 3 7 lbf ft Screw starter cable on starter M5 3 Nm 2 2 lbf ft Spoke nipple rear wheel M5 4 Nm 3 lbf ft Nut foot brake cylinder screw M6 10 Nm 7 4 lbf ft Remaining nuts chassis M6...

Page 176: ...sis M8 25 Nm 18 4 lbf ft Screw bottom triple clamp M8 12 Nm 8 9 lbf ft Screw chain sliding piece M8 15 Nm 11 1 lbf ft Screw connection lever on frame M8 30 Nm 22 1 lbf ft Loctite 243 Screw exhaust cla...

Page 177: ...10 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 40 Nm 29 5 lbf ft Screw side stand M10...

Page 178: ...products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant also in countries with high temperatures Use of low quality antifree...

Page 179: ...e corresponding properties KTM recommends Motorex products Synthetic engine oil Supplier Motorex Motorex KTM Cross Power 4T Engine oil SAE 10W 50 According to JASO T903 MA p 182 SAE p 182 SAE 10W 50 G...

Page 180: ...ic fluid 15 According to ISO VG 15 Guideline Use only hydraulic oil that complies with the specified standard see specifications on the container and that possesses the corre sponding properties KTM r...

Page 181: ...SUBSTANCES 179 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91...

Page 182: ...and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Supplier Motorex Protect Shine High luster polish for paint Guideline KTM recommends Motorex products Su...

Page 183: ...Guideline KTM recommends Motorex products Supplier Motorex Chainlube Offroad Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex...

Page 184: ...e intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with...

Page 185: ...ing 97 Brake linings front brake changing 92 front brake checking 91 rear brake changing 100 rear brake checking 100 Brakes 46 87 103 Braking 46 C Care 149 151 Chain checking 78 cleaning 73 dirt check...

Page 186: ...lectric starter button 22 Electrical system 115 129 Emergency OFF switch 22 Engine running in 37 Engine characteristic adjusting 138 Engine guard installing 86 removing 85 Engine number 17 Engine oil...

Page 187: ...tion 63 adjusting 63 Handrails 33 Headlight light range adjusting 129 Headlight bulb changing 125 Headlight mask with headlight installing 124 removing 122 Headlight setting checking 128 Horn button 2...

Page 188: ...removing 107 Riding 42 starting off 42 Riding instructions 40 50 S Seat mounting 71 removing 70 Seat release 32 Serial numbers 16 18 Service 8 Service schedule 51 53 Service work on the chassis 65 86...

Page 189: ...rques 164 166 fork 170 shock absorber 171 172 Throttle grip 20 Tire air pressure checking 112 Tire condition checking 110 Tires 104 114 Transport 9 Troubleshooting 154 156 Tuning the chassis 54 64 Tun...

Page 190: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 10 2010 Photo Mitterbauer 3211653en 3211653en...

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