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KTM 690 Enduro R EU, Owner'S Manual

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KTM 690 Enduro R EU Owner'S Manual Download Page 49

MAINTENANCE WORK ON CHASSIS AND ENGINE

47

8.46

Checking rear brake fluid level

Warning

Danger of accidents

 

Brake system failure.

–

If the brake fluid level falls below the

MIN

mark, this indicates a leakage in the brake system or worn-out brake linings.

Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Danger of accidents

 

Reduced braking due to old brake fluid.

–

Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

600060-10

–

Stand the vehicle upright.

–

Check the brake fluid level in the brake fluid reservoir

.

» When the fluid level reaches the

MIN

mark

:

–

Top up the brake fluid of the rear brake. (

P. 47)

8.47

Topping up brake fluid of front brake

x

Warning

Danger of accidents

 

Brake system failure.

–

If the brake fluid level falls below the

MIN

mark, this indicates a leakage in the brake system or worn-out brake linings.

Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Skin irritations

 

Brake fluid can cause skin irritation on contact.

–

Avoid contact with skin and eyes, and keep out of the reach of children.

–

If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents

 

Reduced braking due to old brake fluid.

–

Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Environmental hazard

 

Problem materials cause environmental damage.

–

Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

KTM recommends DOT 5.1 brake fluid from

Motorex

®

. This has a higher wet boiling point than DOT 4 brake fluid and provides

greater safety for high demands.
Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

600061-10

–

Stand the vehicle upright.

–

Turn the brake fluid cap

in the direction of the arrow and remove it with mem-

brane

.

–

Top up the brake fluid to level

.

Brake fluid DOT 5.1 (

P. 96)

–

Check parts for damage and wear. Replace damaged or worn parts.

–

Insert the membrane

into the brake fluid reservoir and mount the brake fluid

cap

.

–

Clean up overflowed or spilt brake fluid immediately with water.

Summary of Contents for 690 Enduro R EU

Page 1: ...OWNER S MANUAL 2008 690 Rally Factory Replica ART NO 3211241en ...

Page 2: ......

Page 3: ...te technical specifica tions 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 stop production of a particular model without prior notice KTM accepts no liability for delivery options deviations from illustrations and descriptions as well as printing and other errors The models portrayed...

Page 4: ...ND ENGINE 29 Jacking up the motorcycle 29 Removing the motorcycle from the work stand 29 Checking the basic chassis setting with the rider s weight 29 Compression damping of shock absorber 29 Adjusting compression damping of shock absorber 29 Adjusting rebound damping of the shock absorber 30 Measuring rear wheel sag unloaded 30 Checking static sag of the shock absorber 31 Checking the riding sag ...

Page 5: ...rburetor idle 65 Carburetor adjusting idle x 66 Checking engine oil level 67 Changing engine oil and oil filter cleaning oil screen x 67 Draining the engine oil x 67 Removing the oil filter x 68 Cleaning the oil screen x 69 Mounting oil filter x 70 Filling up with engine oil x 70 Topping up engine oil 71 TROUBLESHOOTING 72 CLEANING 74 Cleaning motorcycle 74 STORAGE 75 Storage 75 Putting the motorc...

Page 6: ...d technical understanding In the interest of your own safety have these jobs done in an authorized KTM workshop There your motorcycle will be serviced optimally by specially trained experts using the specialist tools required Identifies a page reference more information is provided on the specified page Formats used The typographical and other formats used are explained in the following Eigenname ...

Page 7: ... record since otherwise no warranty claims will be recognized No warranty claims can be considered for damage resulting from manipulations and alterations to the motorcycle Fuel oils etc You should use the fuels oils and greases according to specifications as listed in the owner s manual Spare parts accessories For your own safety use only spare parts and accessories approved by KTM KTM accepts no...

Page 8: ...Read this owner s manual carefully and completely before making your first trip It contains a lot of information and tips to help you operate and handle your motorcycle Only then will you find out how to customize the motorcycle ideally for your own use and how you can protect yourself from injury The owner s manual also contains important information on servicing the motorcycle The owner s manual...

Page 9: ...Type label 600001 11 Type label is fixed to the right of the steering head 3 3 Key number 500125 10 The key number is stamped on the key strap 3 4 Engine number 600003 10 The engine number is stamped on the left side of the engine under the engine sprocket 3 5 Fork part number 600002 10 The fork part number is stamped on the inner side of the fork stub ...

Page 10: ...LOCATION OF SERIAL NUMBERS 8 3 6 Shock absorber part number 600026 10 Shock absorber part number is attached at the shock absorber unit to the rear of the direction of travel ...

Page 11: ... 4 Ignition switch 600044 10 The ignition switch is located to the left of the indicator lamp on the instrument support Possible states Ignition off Ignition switch flipped up In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start Ignition on Ignition switch flipped down In this position the ignition circuit is closed and the engine can ...

Page 12: ...he horn is operated in this position 4 8 Flasher switch 600004 10 The flasher switch is fitted on the left side of the handlebar Possible states Flasher light off Flasher switch is in the central position Flasher light left on Flasher switch turned to the left Flasher light right on Flasher switch turned to the right 4 9 Overview of indicator lamps 500147 01 Possible states High beam indicator lam...

Page 13: ... speedometer from the handlebar Info The trip master is an optional accessory 4 13 Setting kilometers or miles Info If you change the unit the ODO value is retained and converted accordingly The values TR1 TR2 A1 A2 and S1 are deleted at the changeover Condition The motorcycle is standing 400329 01 Press the button briefly and repeatedly until H appears at the bottom right of the display Press the...

Page 14: ...ing speedometer functions Info In the condition at delivery only the SPEED H display mode and SPEED ODO are active Condition The motorcycle is standing 400318 01 Press the button briefly and repeatedly until H appears at the bottom right of the display Press the button for 3 5 seconds The Setup menu opens and the active functions are displayed Switch to the function you require by briefly pressing...

Page 15: ...Mph Info Making the setting according to the country When an impulse comes from the front wheel the left side of the speedometer display changes to the SPEED mode and the current speed is shown 4 18 Display mode SPEED H service hours 400316 01 Condition The motorcycle is standing Press the button briefly and repeatedly until H appears at the bottom right of the display In display mode H the servic...

Page 16: ...p Press the button for 3 5 seconds The stop watch and the lap time are reset Press the button briefly Next display mode 4 21 Display mode SPEED ODO odometer 400317 01 Press the button briefly and repeatedly until ODO appears at the bottom right of the display In ODO display mode the total number of kilometers ridden is displayed Press the button No function Press the button No function Press the b...

Page 17: ...y and repeatedly until A1 appears at the top right of the display A1 average speed 1 shows the average speed calculated using TR1 trip master 1 and S1 stop watch 1 The calculation of this value is activated by the first impulse of the wheel sensor and ends 3 seconds after the last impulse Press the button No function Press the button No function Press the button for 3 5 seconds Displays of TR1 A1 ...

Page 18: ...rvice hours No function No function The display changes to the Setup menu of the speedometer functions Next display mode Display mode SPEED CLK time no function no function The display changes to the Setup menu of the clock next display mode Display mode SPEED LAP lap time Starts or stops the clock Stops the current lap time and saves it and the stop watch starts the next lap The stop watch and th...

Page 19: ...SPEED S2 stop watch 2 4 28 Fuses 600029 10 The fuse box is located under the seat 600028 10 Fuse Electric starter system Fuse Radiator fan Fuse Lighting Sentinel optional Fuse Roadbook Fuse not assigned Fuse Lighting Fuse GPS optional Fuse Iritrac optional 4 29 Fuel tank 600045 10 The right fuel tank is filled via filler cap and the left fuel tank is filled via filler cap 600046 10 The rear fuel t...

Page 20: ...r fuel is taken from the two front fuel tanks Only the front fuel tanks empty out completely 600016 10 R REAR If the tap handle of the fuel tap points up fuel is taken from the rear fuel tank Only the rear fuel tank empties out completely 4 31 Choke 600072 10 The chock knob is fitted on the left side of the frame Activating the choke function frees an opening through which the engine can draw extr...

Page 21: ...f damage by the vehicle running away or falling over Always place the vehicle on a firm and even surface Note Material damage Damage and destruction of components by excessive load The side stand is designed for the weight of the motorcycle only Do not sit on the motorcycle when it is supported by the side stand only The side stand and or the frame could be damaged and the motorcycle could fall ov...

Page 22: ...ering lock turn it to the left press it in and turn it to the right Remove the key Steering is no longer possible Info Never leave the key in the steering lock 4 37 Unlocking the steering Insert the key in the steering lock turn it to the left pull it out and turn it to the right Remove the key You can now steer the bike again Info Never leave the key in the steering lock 4 38 Tool set 600104 10 T...

Page 23: ... permitted weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons Info When using your motorcycle remember that others may feel disturbed by excessive noise Make sure that the pre delivery inspection work has been carried out by an authorized KTM workshop You rec...

Page 24: ...ssible front axle load 190 kg 418 87 lb Maximum permissible rear axle load 250 kg 551 15 lb Run the engine in 5 2 Running in the engine During the run in phase do not exceed the specified speed in the respective gear Specification 1st gear 45 km h 27 96 mph 2nd gear 60 km h 37 28 mph 3rd gear 80 km h 49 71 mph 4th gear 95 km h 59 03 mph 5th gear 105 km h 65 24 mph 6th gear 110 km h 68 35 mph ...

Page 25: ...Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in a closed space Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always warm up the engine at low engine speeds Info If the motorcyc...

Page 26: ...ays open the throttle only as much as the engine can handle abrupt throttle opening increases fuel consumption To shift down brake if necessary and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Switch off the engine if you expect to be standing for a long time Specification 2 min Avoid freq...

Page 27: ... fuel tank expands when warm and can escape if the tank is overfilled See specifications on filling up with fuel Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse imme diately with water and contact a doctor Wash affected skin areas immediately with soap and water If fu...

Page 28: ...RIDING INSTRUCTIONS 26 Replace the filler cap and turn clockwise until the tank is tightly closed Info Run the fuel tank breather hoses without kinks ...

Page 29: ...ical equipment is functioning properly Check cables for damage and routing without sharp bends Clean the tank breather hoses checking for damage and routing without sharp bends Check the headlamp setting Treat electric contacts with contact spray Brakes Check the front brake linings P 43 Check the rear brake linings P 48 Check the front brake disc P 41 Check the rear brake disc P 46 Check the fron...

Page 30: ...ng shafts Check the crankshaft connecting rod and cylinder Check the clutch Check the camshaft rocker arm and valves K100A every 10 000 km 6 214 mi J1A annually J2A every 2 years 7 3 Important checks and maintenance work to be carried out by the rider NB1A Check the engine oil level P 67 Check the front brake fluid level P 42 Check the rear brake fluid level P 47 Check the front brake linings P 43...

Page 31: ...ive clothing Specification Standard rider weight 75 85 kg 165 34 187 39 lb If your weight is above or below the standard range you have to adjust the basic setting of the suspension components accord ingly Small weight differences can be compensated by adjusting the spring preload but in the case of large weight differences the springs must be replaced 8 4 Compression damping of shock absorber 600...

Page 32: ...ck absorber is under high pressure The shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any main tenance on it yourself 600053 10 Turn the adjusting screw clockwise until it stops Turn back counterclockwise the number of clicks corresponding to the shock absorber type Specification Rebound damping Standard 22 clicks Info Turn clockwise to ...

Page 33: ... full protective clothing in a normal sitting position feet on footrests and bounce up and down a few times until the rear suspension levels out The other person now has to measure the distance between the rear axle and a fixed point Make a note of the value as measurement Info The riding sag is the difference between measurements and Check the riding sag Riding sag 107 mm 4 21 in If the riding sa...

Page 34: ...f ft Installing shock absorber P 33 8 11 Adjusting riding sag x Remove shock absorber P 32 After removing the shock absorber clean it thoroughly Choose and fit a suitable spring Specification Spring rate 65 75 kg 143 3 165 34 lb 88 N mm 502 49 lb in 75 85 kg 165 34 187 39 lb 92 N mm 525 33 lb in 85 95 kg 187 39 209 44 lb 97 N mm 553 88 lb in Info The spring rate is shown on the outside of the spri...

Page 35: ...tom of the shock absorber but do not tighten it yet Info Ensure that the washers are properly positioned 600094 10 Mount and tighten screw Specification Screw top shock absorber M10 45 Nm 33 19 lbf ft Loctite 243 600095 10 Tighten screw Specification Screw bottom shock absorber M10 45 Nm 33 19 lbf ft Loctite 243 600097 11 Position the splash protector Mount and tighten screws Specification Remaini...

Page 36: ...f the fork legs Make the same adjustment on both fork legs Turn back counterclockwise the number of clicks corresponding to the fork type Specification Rebound damping Standard 20 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce sus pension damping 8 16 Adjusting rebound damping of fork Info The hydraulic rebound damping determines the fork rebound behavior 600050 10 ...

Page 37: ...enetrate behind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray P 98 Press the dust boots back ...

Page 38: ...play of the steering head bearing P 36 Move the handlebar to and fro over the entire steering range The handlebar must be able to move easily over the entire steering range No resting locations should be noticeable If click positions are noticeable Adjust play of the steering head bearing P 36 Check the steering head bearing and replace if required Install the steering damper Remove the motorcycle...

Page 39: ...handlebar clamps Mount and tighten screws Specification Screw handlebar clamp M8 16 Nm 11 8 lbf ft Mount the trim P 54 8 23 Fork offset 400356 10 The fork offset has an impact on the handling of the vehicle It is calculated from the center of the fork leg to the center of the steering head bearing The fork offset can optionally be adjusted 600111 10 When the mark 1 is visible in the bore as delive...

Page 40: ...10 Remove the four screws Remove the holding plate with handlebar clamps with intermediate rubber pieces and elastomers Remove the handlebar and lay it to one side Info Protect the motorcycle and its attachments from damage by covering them Do not bend the cables and lines Remove the lower shells Remove the clamp bar with the rubber cones Remove the two screws Remove the handlebar support Check pa...

Page 41: ... Ensure that the throttle grip automatically returns to the idle position after it is released Install the fuel tank P 56 8 27 Checking chain dirt Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain P 39 8 28 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warnin...

Page 42: ...n positions Chain tension The chain tension is measured while the vehicle is resting on the side stand 5 mm If the chain tension does not meet specifications Adjust the chain tension P 40 8 30 Checking rear sprocket engine sprocket for wear 400227 01 Check rear sprocket engine sprocket for wear If the rear sprocket engine sprocket are worn Replace rear sprocket engine sprocket Info When fitting th...

Page 43: ...e fluid level rises with increasing wear of the clutch lining disc Do not use brake fluid 600112 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove the cover with membrane Check the fluid level Fluid level under top level of container 4 mm 0 16 in If the level of the cooling liquid does not meet specifications Correct the fluid level of the hy...

Page 44: ... Turn the adjustment screw counterclockwise to increase free travel The pressure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding Check the free play of the hand brake lever P 42 8 37 Checking front brake fluid level Warning Danger of accidents Brake system failure If the b...

Page 45: ...rs fuel cleaning substances brake fluid batteries etc according to regulations Info KTM recommends DOT 5 1 brake fluid from Motorex This has a higher wet boiling point than DOT 4 brake fluid and provides greater safety for high demands Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact betw...

Page 46: ...ke linings x Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents Reduced braking due to use of non approved brake linings Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The constru...

Page 47: ...se environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info KTM recommends DOT 5 1 brake fluid from Motorex This has a higher wet boiling point than DOT 4 brake fluid and provides greater safety for high demands Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are no...

Page 48: ... system The rear brake can fail due to overheating Adjust free travel on foot brake pedal according to specifications 400291 11 Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free play Specification Free play at foot brake lever 3 5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the free travel of th...

Page 49: ...and keep out of the reach of children If brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediately Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop Warning Environmental hazard Problem materials cause environmental damage Dispose of oil greas...

Page 50: ...linings P 49 8 49 Removing rear brake linings x Warning Danger of accidents Improper brake maintenance and repair Always have your brake system maintained and repaired in an authorized KTM workshop 600042 10 Press the brake caliper by hand on to the brake disc in order to press back the brake piston Info Make sure when pushing back the brake piston that you do not press the brake caliper against t...

Page 51: ...mage and wear Replace damaged or worn parts Check that the leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly Info The arrow on the leaf spring points in the rotation direction of the brake disc 600065 11 Insert brake linings 600042 11 Mount the bolt with a suitable tool and insert the lock pin Operate the foot brake lever repeatedly until the brak...

Page 52: ...verflows from the reservoir Mount the rear brake linings P 49 Top up the brake fluid to level Brake fluid DOT 5 1 P 96 Check parts for damage and wear Replace damaged or worn parts Insert the membrane into the brake fluid reservoir and mount the brake fluid cap Clean up overflowed or spilt brake fluid immediately with water 8 52 Removing front wheel x Jack up the motorcycle P 29 600031 10 Press th...

Page 53: ...the hand brake lever several times until the brake pads are lying correctly on the brake disc Remove the motorcycle from the work stand P 29 Pull the front wheel brake and push down hard on the fork several times to align the fork legs Tighten screws and Specification Screw fork stub M8 15 Nm 11 06 lbf ft 8 54 Removing rear wheel x Jack up the motorcycle P 29 600035 10 Press the brake caliper by h...

Page 54: ...brake discs free of oil and grease and clean them with brake cleaner when necessary 600037 11 Check parts for damage and wear Replace damaged or worn parts Clean and grease shaft seal rings and bearing surface of the distance bushings Long life grease P 98 Fit the distance bushings 600038 11 Insert the rear sprocket carrier into the rear hub 600036 11 Lift the rear wheel into the swing arm positio...

Page 55: ... have an important impact on the riding behavior of the motorcycle The front and rear wheels must be fitted with tires with similar profiles Worn tires have a negative effect on riding behavior especially on wet surfaces Examine the tires for cuts foreign bodies and other damage Check the depth of the tread Info Note local national regulations concerning the minimum tread depth 2 mm 0 08 in If the...

Page 56: ...rload Check the spoke tension regularly especially on a new motorcycle Check spokes for tightness Specification Spoke nipple front wheel M5 5 Nm 3 69 lbf ft Spoke nipple rear wheel M5 5 Nm 3 69 lbf ft 8 59 Removing the trim 600080 10 Loosen the plug in connectors on the flasher cables 600081 10 Open the quick release brackets and Remove the trim toward the front 8 60 Mounting the trim 600082 10 In...

Page 57: ...cle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See specifications on filling up with fuel Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel...

Page 58: ... Mount the trim P 54 8 65 Folding up the fuel tank at the rear Danger Fire hazard Fuel can easily catch fire Never fill up the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See ...

Page 59: ...ehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See specifications on filling up with fuel Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immedi ately with water and contact a doctor W...

Page 60: ...other 600090 11 Connect the main silencers with the manifolds on both sides Mount the screw on both sides but do not tighten it yet Align the main silencer Mount and tighten screws and on both sides Specification Remaining screws chassis M8 25 Nm 18 44 lbf ft Tighten screw on both sides Specification Remaining screws chassis M6 10 Nm 7 38 lbf ft Mount the seat P 55 8 67 Removing the motor guard 60...

Page 61: ...5 10 On a light colored wall in front of which there is a horizontal surface make a mark at the height of the center of the low beam headlamp Make another mark at a distance below the first mark Specification Distance 5 cm 1 97 in Position yourself with the motorcycle at a distance in front of the wall and switch the low beam on Specification Distance 5 m 16 4 ft Check the headlamp setting For a r...

Page 62: ... mark Tighten screws and Mount the trim P 54 8 71 Removing the battery x Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep the battery away from sparks or open fire Charge only in well ventilated rooms In the event of skin...

Page 63: ... Warning Environmental hazard Components and battery acid are a danger to the environment Do not dispose of batteries in normal household waste Take defective or used batteries to a battery recycling operator Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Even i...

Page 64: ...battery regularly when the motorcycle is not in use 3 months Mount the seat P 55 8 74 Removing the main fuse Switch off all power consuming components and switch off the engine Remove the seat P 55 600108 10 Remove the protection cover Remove the main fuse 8 75 Fitting the main fuse Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses Use only fuses with the pr...

Page 65: ...r cap Check the coolant level in the radiator The radiator must be completely full If the level of the cooling liquid does not meet specifications Correct the coolant level and determine the cause of the loss in coolant Alternative 1 Coolant P 96 Alternative 2 Coolant mixed ready to use P 96 Refit the radiator cap 8 77 Checking coolant level and antifreeze Warning Danger of scalding The coolant ge...

Page 66: ...e 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 dirt can get into the engine and result in increased wear Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Remove the sea...

Page 67: ...never wring it out Oil the dry air filter with a high quality filter oil Oil for foam air filter P 98 Clean the air filter box Check carburetor connection boot for damage and tightness Install the air filter P 64 8 81 Carburetor idle The idle setting of the carburetor has a big influence on the starting behavior stable idling and the response to throttle opening That means that an engine with a co...

Page 68: ...th the highest idle speed Info If there is a big engine speed rise reduce the idle speed to a normal level and repeat the above steps The extreme sport motorcyclist will set the mixture about 1 4 of a turn back from this ideal value leaner in a clockwise direction since the engine becomes hotter in sporting use If the procedure described here does not lead to satisfactory results the cause may be ...

Page 69: ... Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under cold water immediately Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Drain the ...

Page 70: ...cleaning substances brake fluid batteries etc according to regulations Remove the front fuel tank P 55 Place a suitable container under the engine 600083 10 Remove screws Take off the oil filter cover with the O ring 600084 10 Pull the oil filter out of the engine housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean parts and sealing area 600086 11 Disconnect...

Page 71: ...brake fluid batteries etc according to regulations Place a suitable container under the engine 600077 10 Remove plug with oil screen and O ring 600079 10 Remove plug with oil screen and O ring Completely drain the remaining engine oil Thoroughly clean parts and sealing areas Check parts for damage and wear Replace damaged or worn parts 600079 11 Fit and tighten plug with oil screen and O ring Spec...

Page 72: ...fication Screw oil filter cover M5 6 Nm 4 43 lbf ft Install the fuel tank P 56 8 89 Filling up with engine oil x Info Too little engine oil or poor quality engine oil results in premature wear to the engine 600060 11 Remove the screw cap on the clutch cover and fill up with engine oil Engine oil 2 2 l 2 32 qt Engine oil SAE 10W 60 P 96 Engine oil SAE 20W 60 P 97 Mount and tighten screw cap Danger ...

Page 73: ... clutch cover and fill up with engine oil Engine oil SAE 10W 60 P 96 Engine oil SAE 20W 60 P 97 Mount and tighten screw cap Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon sciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in a closed space Start the engine and check that it is oil tigh...

Page 74: ... of the ignition system Have work on the ignition system car ried out in an authorized KTM workshop Remove spark plug connect ignition cable hold spark plug to ground bare metal area on engine and try to start the engine Specification You should see a strong spark on the spark plug If there is no spark change the spark plug If there is still no spark remove the spark plug cap from the ignition cab...

Page 75: ... coolant in cooling system Check the cooling system for leakage Check the coolant level P 63 Too little air stream Switch off engine when standing Radiator fins very dirty Clean radiator fins Bent radiator hose Replace the radiator hose Thermostat defective Have thermostat removed and checked Specification 70 C 158 F Defect in radiator fan system Have the radiator fan system checked Engine has too...

Page 76: ...h a paintbrush Motorcycle cleaner P 98 Info Use warm water containing normal motorcycle cleaner and a soft sponge After rinsing the motorcycle with a gentle water spray allow it to dry thoroughly Warning Danger of accidents Reduced braking due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently After cleaning ride the vehicle a short distance until the engine warms...

Page 77: ... the start of the new season Clean the motorcycle P 74 Change the engine oil and oil filter and clean the oil screen P 67 Check the coolant level and antifreeze P 63 Drain the fuel from the tanks into a suitable container Drain the fuel from the carburetor into a suitable container Checking the tire air pressure P 53 Remove the battery P 60 Recharge the battery P 61 Specification Storage temperatu...

Page 78: ...n lubrication with 2 rotor pumps engine Primary transmission 36 79 Clutch Multidisc clutch in oil bath hydraulically activated Transmission ratio 1st gear 14 35 2nd gear 16 28 3rd gear 21 28 4th gear 23 26 5th gear 24 25 6th gear 25 24 Generator 12 V 224 W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment type Kokusan Spark plug NGK LKAR 8AI 9 spark plug e...

Page 79: ... Screw clutch spring M6 10 Nm 7 38 lbf ft Screw clutch slave cylinder M6x20 10 Nm 7 38 lbf ft Loctite 243 Screw clutch slave cylinder M6x35 10 Nm 7 38 lbf ft Screw engine housing M6 10 Nm 7 38 lbf ft Screw shift drum locating M6 10 Nm 7 38 lbf ft Loctite 243 Screw shift lever M6 10 Nm 7 38 lbf ft Loctite 222 Screw timing chain tensioning rail M6 10 Nm 7 38 lbf ft Loctite 243 Screw stator bracket M...

Page 80: ...ad M12x1 5 12 Nm 8 85 lbf ft Oil drain plug with magnet M12x1 5 20 Nm 14 75 lbf ft Plug excess pressure valve M12x1 5 20 Nm 14 75 lbf ft Spark plug M12x1 25 17 Nm 12 54 lbf ft Plug oil bore M14x1 5 15 Nm 11 06 lbf ft Loctite 243 Ignition rotor nut M18x1 5 100 Nm 73 76 lbf ft Nut engine sprocket M20x1 5 60 Nm 44 26 lbf ft Loctite 243 Nut inner clutch hub M20x1 5 100 Nm 73 76 lbf ft Loctite 243 Nut ...

Page 81: ...plica Carburetor type KEIHIN FCR MX 41 Carburetor identification number 4100B Needle position 5 th position from top Idle mixture adjusting screw Open 2 turns Main jet 168 160 Jet needle OBDVT OBEKR Idling jet 42 45 Main air jet 200 Idle air jet 100 Cold start jet 85 Throttle slide 15 ...

Page 82: ... psi Rear 1 1 5 bar 14 5 21 76 psi Rear wheel gearing 16 44 Rear sprockets available 43 44 45 Chain 5 8 x 1 4 Wheelbase 1535 10 mm 60 43 0 39 in Steering head angle 62 5 Seat height unloaded 980 mm 38 58 in Ground clearance unloaded 320 mm 12 6 in Weight without fuel 162 kg 357 15 lb Maximum permissible front axle load 190 kg 418 87 lb Maximum permissible rear axle load 250 kg 551 15 lb Maximum pe...

Page 83: ...uper unleaded ROZ 95 RON 95 PON 91 P 96 Super unleaded ROZ 98 RON 98 PON 94 P 96 Front right half of tank 9 l 2 38 US gal Super unleaded ROZ 95 RON 95 PON 91 P 96 Super unleaded ROZ 98 RON 98 PON 94 P 96 Rear tank 18 l 4 76 US gal Super unleaded ROZ 95 RON 95 PON 91 P 96 Super unleaded ROZ 98 RON 98 PON 94 P 96 Total fuel filling quantity 36 l 9 51 US gal Super unleaded ROZ 95 RON 95 PON 91 P 96 S...

Page 84: ... spacer s 502 mm 19 76 in Spring rate 65 75 kg 143 3 165 34 lb 4 6 N mm 26 27 lb in 75 85 kg 165 34 187 39 lb 4 8 N mm 27 41 lb in 85 95 kg 187 39 209 44 lb 5 N mm 28 55 lb in Gas pressure 1 2 bar 17 4 psi Fork length 950 mm 37 4 in 16 1 CAPACITY FORK OIL Oil capacity cartridge 195 ml 6 59 fl oz Fork oil SAE 5 P 97 Oil capacity fork tube without cartridge 420 ml 14 2 fl oz Fork oil SAE 5 P 97 ...

Page 85: ... damping low speed Standard 15 clicks Rebound damping Standard 22 clicks Spring preload Standard 14 mm Spring rate 65 75 kg 143 3 165 34 lb 88 N mm 502 49 lb in 75 85 kg 165 34 187 39 lb 92 N mm 525 33 lb in 85 95 kg 187 39 209 44 lb 97 N mm 553 88 lb in Spring length 250 mm 9 84 in Gas pressure 10 bar 145 04 psi Static sag 33 mm 1 3 in Riding sag 107 mm 4 21 in Fitted length 431 mm 16 97 in ...

Page 86: ...Loctite 243 Remaining nuts chassis M8 25 Nm 18 44 lbf ft Remaining screws chassis M8 25 Nm 18 44 lbf ft Screw front brake caliper M8 30 Nm 22 13 lbf ft Loctite 243 Screw foot brake pedal M8 25 Nm 18 44 lbf ft Loctite 243 Screw top triple clamp M8 17 Nm 12 54 lbf ft Screw bottom triple clamp M8 12 Nm 8 85 lbf ft Screw fork stub M8 15 Nm 11 06 lbf ft Screw steer tube M8 25 Nm 18 44 lbf ft Loctite 24...

Page 87: ...85 ...

Page 88: ... 2 4 F A 0 1 1 2 5 F A 5 1 1 2 6 F A 5 1 2 7 F A 5 1 2 8 F A 0 1 1 2 1 F 5 X 6 D 3 2 4 3 1 M 0 3 A 4 E A _ C 1 M 1 G 1 K 4 2 3 1 U C_AU 2 C_BI 2 2 N 1 2 2 1 4 K B _ C 4 R B _ C 6 S 1 3 2 4 5 S 1 2 2 R C _ C G 3 2 G 3 N E _ C 3 M E _ C 6 1 1 0 1 12 13 14 6 0 1 1 1 5 1 5 1 8 4 8 1 8 4 23 6 2 27 26 9 2 29 30 3 4 32 33 3 3 2 3 3 4 41 2 4 42 7 4 7 4 2 5 3 5 2 5 3 5 4 5 55 56 56 9 6 4 6 5 6 3 6 2 6 1 6 ...

Page 89: ...Electric starter button Cable colors 1 green 2 green 3 green 4 green 5 green 6 green 7 yellow red 8 green 9 yellow red 10 yellow red 11 yellow red 12 yellow red 13 yellow red 14 yellow red 15 orange 16 black orange 17 white black 18 yellow blue 19 yellow 20 black red 21 gray 22 yellow 23 yellow 24 green red 25 white yellow 26 blue 27 brown 28 green orange 29 orange 30 brown 31 blue orange 32 brown...

Page 90: ...lack yellow 52 brown 53 brown 54 brown 55 brown 56 black 57 black red 58 black red 59 white green 60 black green 61 green red 62 pink 63 orange 64 white red 65 yellow blue 69 brown 131 yellow 133 black orange 134 orange 135 green 136 green ...

Page 91: ...WIRING DIAGRAM 89 ...

Page 92: ... 2 3 M A _ C 3 R A _ C 1 B 1 2 3 t 2 B 1 1 2 L 1 3 2 4 5 6 8 7 9 0 1 1 1 6 1 5 1 4 1 3 1 2 1 6 1 BX _ C 6 A 1 I E _ C 1 H E _ C 6 X 1 1 2 37 38 0 5 38 32 15 33 40 34 35 36 39 37 0 4 3 3 2 3 5 1 39 34 35 36 50 132 3 2 WIRING DIAGRAM 90 19 2 690 Rally Factory Replica 2 of 3 400350 10 ...

Page 93: ...1 Throttle valve sensor TPS B2 Temperature sensor for indicator lamp L1 Pulse generator L2 Ignition coil Cable colors 15 orange 32 brown 33 brown 34 blue 35 yellow 36 black 37 gray 38 black blue 39 gray 40 black brown 50 black yellow 132 black yellow ...

Page 94: ...1 2 7 1 H 1 2 6 1 H 1 2 5 1 H 3 C 1 7 1 3 1 3 0 3 X 7 0 4 X I H O L t h g i l P 4 3 2 1 5 1 6 C A _ C 1 A B _ C 1 F B _ C 6 C B _ C 9 S 6 C 1 2 4 3 1 C_AH 2 C_AH 2 A5 1 2 1 2 H14 C_DI 2 1 2 3 4 C_CV 4 C_BY 4 H5 C_AK 2 C_AH 2 X403 1 2 2 1 2 2 C_BF 1 C_BA 1 X304 1 2 2 1 2 2 C_BF 1 C_BA 1 X305 1 2 2 1 2 2 C_CY 3 C_CZ 3 C_DA 4 C_DB 4 C_CW 2 C_CX 2 1 2 1 2 3 1 2 3 4 P1 G B3 1 2 6 6 2 6 2 5 2 5 2 8 2 8 ...

Page 95: ...r light optional H15 Flasher indicator light H16 Idling speed indicator lamp H17 Indicator lamp for the coolant temperature H18 High beam indicator light H19 Oil pressure indicator lamp K2 Flasher relay P1 Speedometer S1 Rear brake light switch S3 Oil pressure sensor S7 Front brake light switch S8 Flasher switch Cable colors 19 yellow 25 white yellow 26 blue 28 green orange 29 green 31 blue orange...

Page 96: ...iolet 81 violet 82 black 83 black 84 black 85 black 86 black 87 black 88 black 89 black 90 green white 91 brown 92 white 93 black brown 94 white yellow 95 white 96 white 97 white 98 brown 99 brown 100 brown 101 brown 102 brown 103 green gray 104 blue gray 105 yellow blue 106 yellow blue 107 yellow blue 108 yellow blue 109 yellow blue 110 yellow blue 111 green 112 blue 113 white 114 white 115 white...

Page 97: ...WIRING DIAGRAM 95 116 white 117 white 118 white 119 brown 120 brown 121 brown 122 brown 123 brown 124 brown 125 brown 126 brown 127 black yellow 128 black green 129 red 130 brown ...

Page 98: ... the container and that possesses the corre sponding properties KTM recommends Motorex products Supplier Motorex Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant even in countries with high temperatures Using inferior antifreeze can result in corrosion and foaming KTM recommends Motorex products Mixture ratio 25 45 C 13 49 F 50 Anti corrosion antifreeze 50 distilled water Co...

Page 99: ...and that possess the corre sponding properties KTM recommends Motorex products Synthetic engine oil Supplier Motorex Motorex KTM Racing 4T Fork oil SAE 5 According to SAE SAE 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that possesses the corresponding properties KTM recommends Motorex products Supplier Motorex Motorex Racing Fork Oil ...

Page 100: ...fication KTM recommends Motorex products Supplier Motorex Motorex Long Therm 2000 Cleaning substance for foam air filter Specification KTM recommends Motorex products Supplier Motorex Motorex Twin Air Dirt Bio Remover Oil for foam air filter Specification KTM recommends Motorex products Supplier Motorex Motorex Twin Air Liquid Power Motorcycle cleaner Specification KTM recommends Motorex products ...

Page 101: ...NCES 99 High luster polish for paint Specification KTM recommends Motorex products Supplier Motorex Motorex Moto Polish Contact spray Specification KTM recommends Motorex products Supplier Motorex Motorex Accu Contact ...

Page 102: ... intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle and ATV engines With most motorcycles and ATVs the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for cla...

Page 103: ...el 41 Clutch lever 9 adjusting 41 Compression damping fork adjusting 34 Coolant level checking 63 Coolant level and antifreeze checking 63 D Dust boots cleaning 35 E Electric starter button 9 Engine running in 22 Engine number 7 Engine oil changing 67 draining 67 refilling 70 topping up 71 Engine oil level checking 67 Environment 5 F Filling up Fuel 25 Flasher switch 10 Foot brake pedal 19 adjusti...

Page 104: ... mounting 55 removing 55 Shift lever gears 19 Shifting riding 24 Shock absorber adjusting compression damping 29 Adjusting the rebound damping 30 adjusting the spring preload 31 checking static sag 31 removing 32 Shock absorber part number 8 Short circuit button 9 Side stand 19 Spare parts accessories 5 Speedometer adjusting 12 function description 10 Setting kilometers or miles 11 Setting the clo...

Page 105: ... 3211241en 3211241en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 07 2007 Photo Mitterbauer ...

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