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KTM 690 Enduro R USA 2013, Owner'S Manual

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KTM 690 Enduro R USA 2013 Owner'S Manual Download Page 88

11

SERVICE WORK ON THE CHASSIS

86

11.12

Installing the air filter

x

601785-10

Main work

–

Clean the air filter box.

–

Mount air filter

1

.

Info

The air filter must lie flush against the air filter box along the entire sealing sur-
face

A

.

If the air filter is not correctly mounted, dust and dirt can enter the engine and
cause damage.

–

Hook air filter box top

2

into the front of the air filter box and swing down.

601783-11

–

Mount and tighten screws

3

.

Guideline

Screw, air filter box top

M6

2 Nm (1.5 lbf ft)

Finishing work

–

Mount the seat. (

p. 84)

Summary of Contents for 690 Enduro R USA 2013

Page 1: ...OWNER S MANUAL 2013 690 Enduro R USA Art no 3211952en...

Page 2: ......

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

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

Page 5: ...6 Customer service 20 4 VIEW OF VEHICLE 22 4 1 View of vehicle front left side example 22 4 2 View of vehicle rear right side example 24 5 SERIAL NUMBERS 26 5 1 Chassis number 26 5 2 Type label 26 5...

Page 6: ...pression damping of the shock absorber 68 10 5 Adjusting the low speed compression damping of the shock absorber 68 10 6 Adjusting the high speed compression damping of the shock absorber 69 10 7 Adju...

Page 7: ...9 12 10 Checking rear brake fluid level 110 12 11 Adding rear brake fluid x 111 12 12 Checking the rear brake linings 113 12 13 Changing the rear brake linings x 113 13 WHEELS TIRES 117 13 1 Removing...

Page 8: ...158 17 4 Removing the oil filter x 159 17 5 Cleaning the oil screens x 161 17 6 Installing the oil filter x 163 17 7 Filling up with engine oil x 163 17 8 Adding engine oil 164 18 CLEANING CARE 166 18...

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

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

Page 11: ...hat 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 Id...

Page 12: ...2 SAFETY ADVICE 10 2 4 Overview of labels B01292 10...

Page 13: ...Type label Canada 2 Type label USA 3 Information emission control 4 Information noise emission 5 Information suspension setting 6 Information chain tension 7 Information putting into operation 101615...

Page 14: ...2 SAFETY ADVICE 12 101616 01 Type label USA B01294 01 Information emission control...

Page 15: ...2 SAFETY ADVICE 13 B01295 01 Information noise emission 101619 01 Information suspension setting...

Page 16: ...ives multiple similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become i...

Page 17: ...3V 6B7 Phone 450 441 4451 x 4250 www ktmcanada com 2 7 Operating noise warning This product should be checked for necessary repair or replacement parts if the motorcycle noise has increased significan...

Page 18: ...l or puncturing of the main silencer baffles header pipes or any other components which conduct exhaust gases 2 Removal or puncturing of any part of the intake system 3 Lack of proper maintenance 4 Re...

Page 19: ...sk Wear protective clothing helmet boots gloves pants and jacket with protectors every time you ride the vehicle Always wear protective clothing that is in good condition and meets the legal requireme...

Page 20: ...l of an end of life motorcycle Your authorized KTM dealer will be glad to advise you 2 14 Owner s Manual It is important that you read this Owner s Manual carefully and completely before making your f...

Page 21: ...accessory products that are approved and or recommended by KTM and have them installed by an authorized KTM workshop KTM accepts no liability for other products and any resulting damage or loss Certai...

Page 22: ...ipment In the interest of clarity some components may be shown disassembled or may not be shown at all It is not always necessary to disassem ble the component to perform the activity in question Plea...

Page 23: ...21...

Page 24: ...4 VIEW OF VEHICLE 22 4 1 View of vehicle front left side example B01296 10...

Page 25: ...and brake lever p 29 2 Clutch lever p 29 3 Handrails p 44 4 Filler cap 5 Engine number p 27 6 Shift lever p 45 7 Side stand p 46 8 Seat release p 43 8 Compression damping of the shock absorber p 68 9...

Page 26: ...4 VIEW OF VEHICLE 24 4 2 View of vehicle rear right side example B01297 10...

Page 27: ...3 3 Function buttons p 34 3 Indicator lamps p 35 4 Emergency OFF switch p 32 4 Electric starter button p 32 5 Throttle grip p 30 6 Fork rebound adjustment 7 Shock absorber rebound adjustment 8 Foot br...

Page 28: ...5 SERIAL NUMBERS 26 5 1 Chassis number 601764 10 The chassis number 1 is stamped on the steering head on the right 5 2 Type label B01289 10 The type label 1 is located on the right side of the frame...

Page 29: ...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 100211 10 The engine number 1 is stamped on the l...

Page 30: ...S 28 5 5 Fork part number 601780 10 The fork part number 1 is stamped on the inner side of the fork stub 5 6 Shock absorber part number 101048 10 The shock absorber part number 1 is on the left of the...

Page 31: ...lever 1 is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 6 2 Hand brake lever 601767 10 The hand break lever 1 is fitted on the right side of the han...

Page 32: ...ttle grip 1 is fitted on the right side of the handlebar 6 4 Horn button 601768 12 The horn button 1 is fitted on the left side of the handlebar Possible states Horn button in neutral position Horn bu...

Page 33: ...tched on 6 6 Turn signal switch 601768 11 The turn signal switch 1 is fitted on the left side of the handlebar Possible states Turn signal off Turn signal light left on Turn signal switch pressed to t...

Page 34: ...ted 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 6 8 Electric starter button 601769 11 The...

Page 35: ...y 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...

Page 36: ...eled ODO trip master 1 TRIP 1 and trip mas ter 2 TRIP 2 Press the SET button 2 to reset the trip master 1 function TRIP 1 and trip master 2 func tion TRIP 2 to 0 0 Button 3 has no function 6 10 3 Tach...

Page 37: ...to idle High beam indicator lamp lights up blue High beam is switched on Temperature warning lamp lights up red Coolant temperature has reached a critical value Low fuel warning lamp lights up orange...

Page 38: ...ight up for one second as a function check 400837 01 LEnGth After the display function check the wheel circumference LEnGth is displayed for one sec ond Info 2205 mm equals the circumference of the 21...

Page 39: ...is shown in kilometers per hour km h or in miles per hour mph 6 10 7 Setting kilometers or miles Info If you change the unit the value is retained and converted accordingly Making the setting accordi...

Page 40: ...ep the MODE button pressed until the display mode changes from km h to mph or from mph to km h Guideline Activation duration of MODE button 10 s 6 10 8 Time 400838 11 The time is shown in area 1 of th...

Page 41: ...n and the SET button pressed simultaneously The time is set 6 10 10 ODO display 400839 01 In the ODO display mode the total distance traveled is shown in kilometers or miles Info This value is retaine...

Page 42: ...RIP 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 999 9...

Page 43: ...lamp lights up in parallel to the TRIP F display 6 10 14 Coolant temperature indicator 700124 01 The temperature display consists of 12 bars The more bars that light up the hotter the coolant When the...

Page 44: ...ing 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...

Page 45: ...6 12 Closing filler cap 601771 01 Put the filler cap back on and turn the ignition key 90 clockwise Remove the ignition key and fold down the cover 6 13 Seat release 601772 10 The seat can be released...

Page 46: ...have a passenger the passenger can hold on the handrails during the journey 6 15 Passenger footrests 601774 01 The passenger footrests can be folded up and down Possible states Passenger footrests fo...

Page 47: ...6 16 Shift lever 100215 10 The shift lever 1 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...

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

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

Page 50: ...your first trip read the entire operating instructions carefully Get to know the controls Adjust the basic position of clutch lever p 97 Adjust the free travel of the hand brake lever p 100 Adjust th...

Page 51: ...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 man...

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

Page 53: ...level p 110 Check the front brake linings p 104 Check the rear brake linings p 113 Check the brake system function Check the coolant level p 147 Check the chain for dirt p 87 Check the chain tension...

Page 54: ...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 li...

Page 55: ...n a gear is engaged If the side stand is folded out and you shift into gear and release the clutch lever the engine stops Take the weight off the side stand and swing it back up with your foot as far...

Page 56: ...rning the minimum age of passengers in your country Warning Danger of accidents Danger of accidents caused by dangerous driving Comply with traffic regulations and ride defensively and foresightedly t...

Page 57: ...le as usual before preparing for use 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 dirt...

Page 58: ...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 and...

Page 59: ...em by riding 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 aut...

Page 60: ...engine As a result you will have to apply the brakes far less frequently and the brake system will not overheat 8 6 Stopping parking Warning Risk of misappropriation Usage by unauthorized persons Nev...

Page 61: ...s switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock power continues to flow to most power consumers and the battery will discharge You should therefo...

Page 62: ...le Never refuel 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 imme...

Page 63: ...refuel with clean fuel that meets the specified standards Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the grou...

Page 64: ...button 2 for two seconds The fuel level warning lamp 1 switches off TRIP F is set to 0 0 and the display returns to the previous display mode Info If you do not press the SET button 2 the reset takes...

Page 65: ...e and leakage Check the rear brake fluid level p 110 Check the free travel of the foot brake lever p 109 Check that the shock absorber and fork are leak tight If necessary and depending on use service...

Page 66: ...uted without sharp bends and set correctly Change the air filter Clean the air filter box x Check the fuel pressure x Check the CO adjustment with the KTM diagnostics tool x Check rectify the fluid le...

Page 67: ...9 SERVICE SCHEDULE 65 K10N Once after 1 000 km 621 4 mi K100A Every 10 000 km 6 214 mi or annually or after every sporting use K200A Every 20 000 km 12 428 mi or every 2 years...

Page 68: ...he basis of your own personal suspension setting Do not change the settings at random or by more than 40 since otherwise the riding characteristics could deteriorate particularly at high speeds 10 2 A...

Page 69: ...se to reduce damping 10 3 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork rebound behavior 601776 10 Turn adjusting screws 1 clockwise all the way Info...

Page 70: ...the 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 71: ...o the 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 counterclockw...

Page 72: ...he shock 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 red...

Page 73: ...cks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 10 8 Measuring the unloaded rear wheel sag Preparatory wor...

Page 74: ...loaded p 71 Hold the motorcycle 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 B Info The static sag is the...

Page 75: ...now measures the distance between the rear axle and a fixed point Note down the value as dimension C Info The riding sag is the difference between measurements A and C Check the riding sag Riding sag...

Page 76: ...roughly 201271 11 Main work Release retaining ring 1 Turn adjusting ring 2 until the spring is fully relaxed Hook wrench T106S Measure the overall spring length without a load Tighten the spring by tu...

Page 77: ...ck absorber clean it thoroughly 201352 10 Main work Choose and mount a suitable spring Guideline Spring rate Medium standard 80 N mm 457 lb in Hard 85 N mm 485 lb in Info The spring rate is shown on t...

Page 78: ...e installed in the position most comfortable for the rider 10 14 Adjusting handlebar position x 401454 10 Remove the four screws 1 Remove the handlebar clamp Remove the handlebar and lay it to one sid...

Page 79: ...CHASSIS 77 Position the handlebar Info Make sure cables and wiring are positioned correctly Position the handlebar clamp Fit and evenly tighten the four screws 1 Guideline Screw handlebar clamp M8 20...

Page 80: ...vehicle on a firm and even surface 601778 01 Raise the motorcycle using the underride guard under the motorcycle The wheels must no longer touch the ground Secure the motorcycle against falling over 1...

Page 81: ...side stand Remove the lift stand 11 3 Bleeding the fork legs Preparatory work Lean the motorcycle on the side stand 601779 10 Main work Briefly loosen bleeder screws 1 Any excess pressure escapes fro...

Page 82: ...hind the dust boots If this dirt is not removed the oil seals behind the dust boots can start to leak Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Alw...

Page 83: ...he fork protector downward 11 6 Positioning the fork protector B01282 11 Position the fork protector on the left fork leg Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf...

Page 84: ...ift stand p 78 100298 10 Main work Move the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel No play should be noticeable in the steering head bearing...

Page 85: ...retighten screw 3 Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid strains Fully tighten screws 1 Guideline Screw top tr...

Page 86: ...the seat and lift it off 11 10 Mounting the seat 601782 10 Hook slot 1 of the seat onto screw 2 press the rear downward and at the same time push it forward Push locking pin 3 into lock housing 4 and...

Page 87: ...83 10 Main work Remove screws 1 Take off air filter box top 2 601784 10 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never ride the vehicle without...

Page 88: ...sh against the air filter box along the entire sealing sur face A If the air filter is not correctly mounted dust and dirt can enter the engine and cause damage Hook air filter box top 2 into the fron...

Page 89: ...heir grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil...

Page 90: ...g Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bearings in transmission...

Page 91: ...et specifications Adjust the chain tension p 89 11 16 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components o...

Page 92: ...ing screws 3 so that the markings on the left and right chain adjusters 4 are in the same position relative to the reference marks C The rear wheel is then correctly aligned Info The upper chain secti...

Page 93: ...atory work Raise the motorcycle with the lift stand p 78 100132 10 Main work Shift gear to neutral Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are wor...

Page 94: ...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 B at the longest chain section 272 mm 10 71...

Page 95: ...r 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 Tigh...

Page 96: ...nge 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...

Page 97: ...IS 95 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 Finishing work Remove the motorcy...

Page 98: ...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 Inse...

Page 99: ...nd only and do not apply any force Do not make any adjustments while riding 601786 10 Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw 1 When adjusting the clu...

Page 100: ...4 mm 0 16 in If the level of the coolant does not meet specifications Correct the fluid level of the hydraulic clutch Hydraulic fluid 15 p 195 Position the cover with the membrane Mount and tighten th...

Page 101: ...THE CHASSIS 99 11 22 Installing the engine guard 202021 11 Slide the engine guard into holders 1 at the rear Position the engine guard Mount and tighten screws 2 Guideline Remaining screws chassis M6...

Page 102: ...t the free travel on hand brake lever according to specifications 601805 10 Push the hand brake to the handlebar and check free travel A Free travel of hand brake lever 3 mm 0 12 in If the free travel...

Page 103: ...ding 12 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...

Page 104: ...system 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 efficiency due to old b...

Page 105: ...ith the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front...

Page 106: ...e screws Info Clean up overflowed or spilt brake fluid immediately with water 12 6 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings...

Page 107: ...nd repairs 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 eye...

Page 108: ...derably 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...

Page 109: ...sc in order to retract the brake pistons Ensure that brake fluid does not flow out of the brake fluid reservoir extracting it by suction if it does Info Make sure when pushing back the brake pistons t...

Page 110: ...ount 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 601806 12 Adjust the brake fluid level to level A G...

Page 111: ...ck 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...

Page 112: ...foot brake lever has the necessary free travel Hold screws 3 in place and tighten the nuts Guideline Screw connection foot brake cylinder M6 10 Nm 7 4 lbf ft Check the free travel of the foot brake le...

Page 113: ...ng rear 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 C...

Page 114: ...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 par...

Page 115: ...e disc The braking effect is greatly reduced and the brake discs are destroyed Check the brake linings regularly 100260 10 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 04...

Page 116: ...the 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 a...

Page 117: ...e vehicle upright Remove screw cap 1 with membrane 2 Press the brake caliper by hand onto the brake disc in order to retract the brake piston Ensure that brake fluid does not flow out of the brake flu...

Page 118: ...brake linings insert the pin 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 Adjust the brake...

Page 119: ...the front wheel x Preparatory work Raise the motorcycle with the lift stand p 78 601807 10 Main work Press the brake caliper by hand on to the brake disc in order to press back the brake pistons 60180...

Page 120: ...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 3 13 2 Installing the front wheel x Warning Danger of accidents Re...

Page 121: ...on the front wheel and insert the wheel spindle The brake linings are correctly positioned Mount and tighten screw 2 Guideline Screw front wheel spindle M24x1 5 45 Nm 33 2 lbf ft Activate the hand bra...

Page 122: ...move chain adjuster 2 Holding the rear wheel withdraw the wheel spindle 3 100268 01 Push the rear wheel forwards as far as possible and take the chain off the rear sprocket Warning Danger of accidents...

Page 123: ...erate the foot brake until the pressure point is reached Main work Check the rear hub rubber dampers x p 122 100269 10 Check the wheel bearing for damage and wear If the wheel bearing is damaged or wo...

Page 124: ...uideline 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 there is a pressure point Finishing wor...

Page 125: ...the rear wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub To check play A hold the rear wheel tight and try to rotate the rear sprocket with your han...

Page 126: ...ncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Warning Danger of...

Page 127: ...the tires Info The tire s date of manufacture is usually part of the tire markings and is indi cated by the last four digits of the DOT marking The first two digits refer to the week of manufacture a...

Page 128: ...8 bar 26 psi Rear 1 8 bar 26 psi Tire air pressure with passenger fully loaded Front 2 0 bar 29 psi Rear 2 2 bar 32 psi If the tire pressure does not meet specifications Correct the tire pressure Mou...

Page 129: ...ecially on a new motorcycle 400694 01 Briefly strike each spoke with a screwdriver blade Info The frequency of the tone is a function of the spoke length and spoke diameter If you hear different tone...

Page 130: ...t least 15 minutes and contact a physician Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 84 601812 10 Main work Disconnect the negative minus cable of the...

Page 131: ...Info The battery terminals must be at the rear Attach the positive cable and mount positive terminal cover 1 Position retaining bracket 2 Mount and tighten screws 3 Guideline Remaining screws chassis...

Page 132: ...amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Warning Environmental hazard The battery contains elements that are harmful to the e...

Page 133: ...are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If...

Page 134: ...rnator With this device you cannot overcharge the battery Info Never remove lid 1 Charge the battery with a maximum of 10 of the capacity specified on the bat tery housing 2 Switch off and disconnect...

Page 135: ...Use only fuses with the prescribed amperage Never by pass or repair fuses Info The main fuse protects all power consumers in the vehicle It is in the housing of the starter relay next to the battery P...

Page 136: ...ter relay Check the functioning of the electrical equipment Mount the protection covers Finishing work Mount the seat p 84 Set the clock p 38 14 5 Changing fuses of individual power consumers Info The...

Page 137: ...ontrol unit Fuse 4 10 A fuel pump Fuse 5 10 A radiator fan Fuse 6 10 A horn brake light turn signal Fuse 7 15 A high beam low beam parking light tail light license plate lamp Fuse 8 10 A for supplemen...

Page 138: ...es Replace with a spare fuse of the right rating Fuse 75011088010 p 185 Fuse 75011088015 p 185 Tip Put a new spare fuse in the fuse box for future use if needed Check the function of power consumers C...

Page 139: ...93 10 Main work Cover the fender with a cloth to protect it from damage Remove screws 1 on both sides Tip the headlight mask forward 601794 10 Disconnect the connectors of turn signals 2 and headlight...

Page 140: ...t mask with the headlight 601794 11 Main work Connect the connectors of headlight 1 and turn signal lights 2 Check lighting function 601810 10 Remove the cloth from the fender and position the headlig...

Page 141: ...eadlight setting p 143 14 8 Changing the headlight bulb Note Damage to reflector Reduced brightness Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp a...

Page 142: ...spring bar 3 Remove headlight bulb 4 Insert a new headlight bulb into the headlight housing Headlight H4 socket P43t p 186 Fix the headlight bulb in the headlight using the spring bar Mount the protec...

Page 143: ...ease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off all power consumers and switch o...

Page 144: ...1x9 5d p 186 Insert the bulb socket in the reflector Insert the protection cap Finishing work Install the headlight mask with the headlight p 138 Check the headlight setting p 143 14 10 Changing the...

Page 145: ...t stops Turn signal RY10W socket BAU15s p 186 Position the diffuser Insert the screw and turn it counterclockwise first until it engages in the thread Tighten the screw slightly Finishing work Check t...

Page 146: ...specifications Adjust the headlight range p 144 14 12 Adjusting the headlight range Preparatory work Check the headlight setting p 143 601796 10 Main work Turn adjusting screw 1 to adjust the headlig...

Page 147: ...ture without causing any malfunctions 125 C 257 F 400407 10 Cooling takes place by means of the air stream and a radiator fan 4 which is controlled by a thermoswitch The lower the speed the less the c...

Page 148: ...of the reach of children Condition Engine is cold B01293 10 Stand the motorcycle on its side stand on a horizontal surface Remove the cap of compensating tank 1 Check antifreeze of coolant 25 45 C 13...

Page 149: ...specifications Correct the coolant level and find out the cause of the loss Alternative 1 Coolant p 193 Alternative 2 Coolant mixed ready to use p 193 Mount the radiator cap 15 3 Checking the coolant...

Page 150: ...dren Condition Engine is cold B01293 10 Stand the motorcycle on its side stand on a horizontal surface Check the coolant level in the compensating tank 1 The coolant level must be within the range sho...

Page 151: ...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 152: ...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 and water If coolant is swallowed contact a docto...

Page 153: ...t gases are toxic and inhaling them 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 enclose...

Page 154: ...poisoning Exhaust gases are toxic and inhaling them 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 engi...

Page 155: ...ay in the throttle cable by turning adjusting screw 2 Guideline Throttle cable play 3 5 mm 0 12 0 2 in Tighten lock nut 1 16 3 Adjusting the engine characteristic Preparatory work Switch off the ignit...

Page 156: ...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 Map Se...

Page 157: ...ine distance A between the upper edge of your boot and the shift lever Distance between shift lever and upper edge of boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the...

Page 158: ...ever 2 on the shift shaft in the required position and engage the gear ing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle components during t...

Page 159: ...ng temperature Preparatory work Stand the motorcycle upright on a horizontal surface 601818 10 Main work Check the engine oil level Info After switching off the engine wait one minute before checking...

Page 160: ...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 lukewarm w...

Page 161: ...clean 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 17 4 Removing the oil filte...

Page 162: ...lace a suitable container under the engine 100202 10 Main work Remove screws 1 Remove the oil filter cover 2 with the O ring Pull oil filter 3 out of the oil filter housing Circlip pliers reverse 5101...

Page 163: ...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 brake fluid etc...

Page 164: ...Thoroughly clean the parts and sealing area 100207 10 Position oil screen 2 with the O rings Mount and tighten screw plug 1 with the O ring Guideline Plug oil screen M20x1 5 15 Nm 11 1 lbf ft 100208 1...

Page 165: ...rew oil filter cover M5 6 Nm 4 4 lbf ft 17 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 Main work Remove fille...

Page 166: ...ne and check that it is oil tight Finishing work Install the engine guard p 99 Check the engine oil level p 157 17 8 Adding engine oil Info Too little engine oil or poor quality engine oil results in...

Page 167: ...oxic and inhaling them 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 witho...

Page 168: ...rs brake fluid etc should be disposed of as stipulated in applicable regulations Info If you clean the motorcycle regularly its value and appearance will be maintained over a long period Avoid direct...

Page 169: ...o evaporate Push back the protection covers of the handlebar controls to allow any water that has penetrated to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Cl...

Page 170: ...e p 166 Clean the brake system Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after the parts are cool...

Page 171: ...refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 197 Clean the motorcycle p 166 Change the engine oil and filter clean the oil screens x p 158...

Page 172: ...or a short time only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 19 2 Preparing for use after storage 401...

Page 173: ...eutral Engine turns but does not start Operating error Carry out the start procedure p 52 Fuse 4 blown Change the fuses of individual power consumers p 134 Coupling of fuel hose connection not connect...

Page 174: ...e KTM diag nostics tool x Engine dies during the journey Lack of fuel Refuel p 60 Fuse 1 2 or 4 blown Change the fuses of individual power consumers p 134 High oil consumption Engine vent hose bent Ro...

Page 175: ...ernator Check the charging voltage x Check the quiescent current x Combination instrument shows nothing in the display Fuse 1 blown Change the fuses of individual power consumers p 134 Set the clock p...

Page 176: ...y 9x Error level condition Manifold absolute pressure sensor cylinder 1 input signal too low Manifold absolute pressure sensor cylinder 1 input signal too high Blink code FI of warning lamp MIL 12 FI...

Page 177: ...evel condition Rollover sensor input signal too low Rollover sensor input signal too high Blink code FI of warning lamp MIL 17 FI warning lamp MIL flashes 1x long 7x short Error level condition Lambda...

Page 178: ...Error level condition Fuel pump controller short circuit to ground or open circuit Fuel pump controller input signal too high Blink code FI of warning lamp MIL 45 FI warning lamp MIL flashes 4x long...

Page 179: ...x 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 Bli...

Page 180: ...21 BLINK CODE 178 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 181: ...Valve diameter 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 Piston pin with DLC coating Pis...

Page 182: ...starter automatic decompressor 22 2 Engine tightening torques Screw membrane fixation M3 2 Nm 1 5 lbf ft Loctite 243 Hose clip intake flange M4 2 5 Nm 1 84 lbf ft Oil nozzle for conrod bearing lubrica...

Page 183: ...w cylinder head M6 10 Nm 7 4 lbf ft Loctite 243 Screw engine case M6 10 Nm 7 4 lbf ft Screw ignition pulse generator M6 10 Nm 7 4 lbf ft Loctite 243 Screw locking lever M6 10 Nm 7 4 lbf ft Loctite 243...

Page 184: ...hain shaft Step 1 15 Nm 11 1 lbf ft Step 2 30 Nm 22 1 lbf ft Step 3 45 Nm 33 2 lbf ft Step 4 60 Nm 44 3 lbf ft Lubricated with engine oil Oil line for oil pressure sensor M10x1 10 Nm 7 4 lbf ft Oil pr...

Page 185: ...Nut inner clutch hub M20x1 5 100 Nm 73 8 lbf ft Loctite 243 Nut primary gear M20LHx1 5 90 Nm 66 4 lbf ft Loctite 243 Plug oil screen M20x1 5 15 Nm 11 1 lbf ft Plug timing chain tensioner M20x1 5 25 Nm...

Page 186: ...ion 4860 MXMA Shock absorber WP Suspension 4618 with Pro Lever deflector Suspension travel Front 250 mm 9 84 in Rear 250 mm 9 84 in Brake system Front Disc brake with dual piston brake caliper floatin...

Page 187: ...elbase 1 504 15 mm 59 21 0 59 in Seat height unloaded 935 mm 36 81 in Ground clearance unloaded 280 mm 11 02 in Weight without fuel approx 142 kg 313 lb Maximum permissible front axle load 150 kg 331...

Page 188: ...5W socket BAY15d 12 V 21 5 W License plate lamp W5W socket W2 1x9 5d 12 V 5 W 22 6 Tires Front tires Rear tires 90 90 21 M C 54R TT Pirelli MT 21 RALLYCROSS 140 80 18 M C 70R TT Pirelli MT 21 RALLYCRO...

Page 189: ...29 7 lb in Medium standard 5 4 N mm 30 8 lb in Hard 5 6 N mm 32 lb in Air chamber length 120 20 mm 4 72 0 79 in Fork length 890 mm 35 04 in Fork oil per fork leg 620 ml 20 96 fl oz Fork oil SAE 4 486...

Page 190: ...ort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload 20 mm 0 79 in Spring rate Medium standard 80 N mm 457 lb in Hard 85 N mm 485 lb in Spring length 220 mm 8 66 in G...

Page 191: ...ft Loctite 243 Spoke nipple front wheel M4 5 3 6 Nm 2 2 4 4 lbf ft Bolt foot brake lever stub M5 6 Nm 4 4 lbf ft Loctite 243 Remaining nuts chassis M5 4 Nm 3 lbf ft Remaining screws chassis M5 4 Nm 3...

Page 192: ...ard M6 8 Nm 5 9 lbf ft Loctite 243 Screw fan hood M6 4 Nm 3 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 lower radiator brac...

Page 193: ...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 handlebar clamp M8 20 Nm 14 8 lbf ft Screw handrai...

Page 194: ...43 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 Screw swingarm pivot M12 80 Nm 59 lbf ft Lambda sensor M12x1 25 25 Nm 18 4 lbf ft Coppe...

Page 195: ...x products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant also in countries with high temperatures Use of low quality antifre...

Page 196: ...sess the corresponding properties KTM recommends Motorex products Synthetic engine oil Supplier Motorex Cross Power 4T Engine oil SAE 10W 50 According to JASO T903 MA p 200 SAE p 200 SAE 10W 50 Guidel...

Page 197: ...l that complies with the specified standard see specifications on the container and that possesses the corre sponding properties KTM recommends Motorex products Supplier Motorex Hydraulic Fluid 75 Sho...

Page 198: ...aded 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 to use Info Do not use fuel containing methanol e g M15 M85 M100 or...

Page 199: ...ng and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Supplier Motorex Protect Shine Fuel additive Guideline KTM recommends Motorex products Supplier Motor...

Page 200: ...er Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Off road chain spray Guideline KTM recommends Motorex products Supplier Motorex Chainlube Offroad Paint cleaner and polish...

Page 201: ...24 AUXILIARY SUBSTANCES 199 Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Synthetic...

Page 202: ...vice intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated wit...

Page 203: ...ake fluid level front brake checking 102 rear brake checking 110 Brake linings front brake changing 105 front brake checking 104 rear brake changing 113 rear brake checking 113 Brakes 57 Braking 57 C...

Page 204: ...149 Coolant level checking 145 147 Cooling system 145 filling bleeding 150 Customer service 20 E Electric starter button 32 Emergency OFF switch 32 Engine running in 48 Engine characteristic adjustin...

Page 205: ...e travel checking 100 Handlebar position 76 adjusting 76 Handrails 44 Headlight light range adjusting 144 Headlight bulb changing 139 Headlight mask with headlight installing 138 removing 136 Headligh...

Page 206: ...ecking 91 Rear wheel installing 121 removing 120 Riding 53 starting off 53 Riding sag adjusting 75 S Safe operation 16 Seat mounting 84 removing 84 Seat release 43 Service 19 Service schedule 63 65 Sh...

Page 207: ...ctrical system 185 engine 179 engine tightening torques 180 fork 186 shock absorber 187 tires 186 Throttle grip 30 Tire air pressure checking 125 Tire condition checking 124 Transport 59 Troubleshooti...

Page 208: ...3211952en 3211952en 11 2012 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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