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KTM 690 Enduro R USA, Owner'S Manual

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KTM 690 Enduro R USA Owner'S Manual Download Page 157

17

SERVICE WORK ON THE ENGINE

155

17.1

Checking the engine oil level

Info

The engine oil level must be checked when the engine is warm.

Condition

The engine is at operating 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 the level.

The engine oil must be between the lower and upper edge of the oil level viewer.

» If the engine oil level is not at the specified level:

–

Add the engine oil. (

p. 162)

Summary of Contents for 690 Enduro R USA

Page 1: ...OWNER S MANUAL 2014 690 Enduro R EU 690 Enduro R AUS UK Art no 3213101en...

Page 2: ......

Page 3: ...All 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 wit...

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: ...s number 20 5 2 Type label 20 5 3 Key number 21 5 4 Engine number 21 5 5 Fork part number 22 5 6 Shock absorber part number 22 6 CONTROLS 23 6 1 Clutch lever 23 6 2 Hand brake lever 23 6 3 Throttle gr...

Page 6: ...n damping of the shock absorber 65 10 7 Adjusting the rebound damping of the shock absorber 66 10 8 Measuring the unloaded rear wheel sag 67 10 9 Checking the static sag of the shock absorber 68 10 10...

Page 7: ...wheel x 114 13 2 Installing the front wheel x 115 13 3 Removing rear wheel x 117 13 4 Installing the rear wheel x 118 13 5 Checking the rear hub rubber dampers x 120 13 6 Checking the tire condition...

Page 8: ...8 Adding engine oil 162 18 CLEANING CARE 164 18 1 Cleaning the motorcycle 164 18 2 Checks and maintenance steps for winter operation 166 19 STORAGE 168 19 1 Storage 168 19 2 Preparing for use after st...

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: ...n Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken 2 4 Tampering warning Tampering with the noise control system is prohibited Federal law p...

Page 12: ...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 exhaust...

Page 13: ...s In some instances a thread locker e g Loctite is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them for damage and...

Page 14: ...hen will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it as...

Page 15: ...nd auxiliary substances such as fuel and lubricants as specified in the Owner s Manual 3 3 Spare parts accessories For your own safety only use spare parts and accessory products that are approved and...

Page 16: ...observe these exactly you will ensure a much longer service life for your motorcycle 3 5 Figures The figures contained in the manual may depict special equipment In the interest of clarity some compon...

Page 17: ...15...

Page 18: ...4 VIEW OF VEHICLE 16 4 1 View of vehicle front left side example B01940 10...

Page 19: ...4 VIEW OF VEHICLE 17 1 Hand brake lever p 23 2 Clutch lever p 23 3 Handrails p 38 4 Filler cap 5 Engine number p 21 6 Shift lever p 39 7 Side stand p 41 8 Seat release p 38 9 Passenger footrests p 39...

Page 20: ...4 VIEW OF VEHICLE 18 4 2 View of vehicle rear right side example B01941 10...

Page 21: ...1 Horn button p 24 2 Ignition steering lock p 27 3 Function buttons p 28 3 Indicator lamps p 29 4 Emergency OFF switch p 26 4 Electric starter button p 26 5 Throttle grip p 24 6 Foot brake lever p 40...

Page 22: ...5 SERIAL NUMBERS 20 5 1 Chassis number 401945 10 The chassis number is stamped on the steering head on the right 5 2 Type label B01942 10 The type label is located on the right side of the frame...

Page 23: ...he key number can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place 5 4 Engine number 401949 10 The engine number is stamped on the lef...

Page 24: ...ERS 22 5 5 Fork part number 401947 10 The fork part number is stamped on the inner side of the fork stub 5 6 Shock absorber part number 402025 10 The shock absorber part number is on the left of the s...

Page 25: ...h lever is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 6 2 Hand brake lever B01944 10 The hand break lever is fitted on the right side of the handl...

Page 26: ...rottle grip is fitted on the right side of the handlebar 6 4 Horn button B01946 10 The horn button is fitted on the left side of the handlebar Possible states Horn button in neutral position Horn butt...

Page 27: ...tched on 6 6 Turn signal switch B01946 12 The turn signal switch is fitted on the left side of the handlebar Possible states Turn signal off Turn signal light left on Turn signal switch pressed to the...

Page 28: ...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 B01947 11 The...

Page 29: ...key can be removed Ignition ON In this position the ignition circuit is closed and the engine can be started Steering locked In this position the ignition circuit is interrupted and the steering lock...

Page 30: ...DO trip master 1 TRIP 1 and trip mas ter 2 TRIP 2 Press the SET button to reset the trip master 1 function TRIP 1 and trip master 2 func tion TRIP 2 to 0 0 The ABS can be switched off using button 6 1...

Page 31: ...beam is switched on Temperature warning lamp lights up red Coolant temperature has reached a critical value Low fuel warning lamp lights up orange Fuel level has reached the reserve mark Display swit...

Page 32: ...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 33: ...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 accordin...

Page 34: ...eep 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 of the...

Page 35: ...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 36: ...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 37: ...mark the display automatically changes to TRIP F and starts to count from 0 0 regardless of the previous display mode Info The low fuel warning lamp lights up in parallel to the TRIP F display 6 10 1...

Page 38: ...always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if...

Page 39: ...ound or the sewage system 601770 10 Lift the cover of filler cap and insert the ignition key Turn the ignition key 90 counterclockwise and remove the filler cap Info The filler cap has a fuel tank bre...

Page 40: ...t release B01948 10 The seat can be released using strap 6 14 Handrails 601773 10 The handrails are used for moving the motorcycle around When you have a passenger the passenger can hold on the handra...

Page 41: ...footrests can be folded up and down Possible states Passenger footrests folded up For operation without a passenger Passenger footrests folded down For operation with a passenger 6 16 Shift lever 4019...

Page 42: ...s can be seen in the photograph The neutral or idle position is between the first and second gears 6 17 Foot brake lever 401956 10 Foot brake lever is located in front of the right footrest The rear b...

Page 43: ...nd must be folded up during motorcycle use The side stand is coupled with the safety starting system see the riding instruc tions Possible states Side stand folded out The vehicle can be supported on...

Page 44: ...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 45: ...ore your first trip read the entire operating instructions carefully Get to know the controls adjust the basic position of clutch lever p 93 Adjust the free travel of the hand brake lever Adjust the b...

Page 46: ...lmet 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 manuf...

Page 47: ...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 48: ...fluid level p 107 Check the front brake linings p 101 Check the rear brake linings p 110 Check the brake system function Check the coolant level p 147 Check the chain for dirt p 83 Check the chain te...

Page 49: ...ver 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 life of the engine Always warm up th...

Page 50: ...equipped with a safety starting system You can only start the engine if the transmission is in neutral or if the clutch lever is pulled when a gear is engaged If the side stand is folded out and you s...

Page 51: ...lock up Warning Danger of accidents Malfunctions caused by incorrect ignition key position Do not change the ignition key position during a journey Warning Danger of accidents Distraction from traffi...

Page 52: ...the tires have been run in Warning Danger of accidents Unstable handling characteristics Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational...

Page 53: ...r release the clutch and open the throttle Info You can see the positions of the 6 forward gears in the figure The neutral or idle position is between the first and second gears First gear is used for...

Page 54: ...lash Info From the flashing rhythm you can derive a two digit number the so called blink code The blink code tells you which component has a fault 8 5 Braking Warning Danger of accidents Reduced braki...

Page 55: ...ater stopping distance due to ABS Braking should be appropriate to the driving situation and the road conditions Warning Danger of accidents Excessively forceful braking can cause the wheels to block...

Page 56: ...rized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons If you leave the vehicle lock the steering and remove the ignition key Warning...

Page 57: ...ignition lock power continues to 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 intende...

Page 58: ...he 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 The fuel...

Page 59: ...ly 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 gr...

Page 60: ...SET button for two seconds The fuel level warning lamp 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 the reset takes pl...

Page 61: ...k the front brake linings p 101 Check the rear brake linings p 110 Check the brake discs p 98 Check the brake lines for damage and leakage Check the rear brake fluid level p 107 Check the free travel...

Page 62: ...incorrect routing x Check the antifreeze and coolant level p 145 Check the cables for damage and routing without sharp bends x Change the air filter Clean the air filter box x Check the fuel pressure...

Page 63: ...9 SERVICE SCHEDULE 61 One time interval Periodic interval...

Page 64: ...nge the settings at random or by more than 40 since otherwise the riding characteristics could deteriorate particularly at high speeds 10 2 Adjusting the compression damping of the fork Info The hydra...

Page 65: ...the fork Info The hydraulic rebound damping determines the fork rebound behavior B01949 11 Turn the red adjusting screw all the way clockwise Info Adjusting screw is located at the upper end of the ri...

Page 66: ...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 67: ...e 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 68: ...hock 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...

Page 69: ...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 70: ...unloaded p 67 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 Info The static sag is the...

Page 71: ...n 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 8...

Page 72: ...r clean it thoroughly 201271 11 Main work Release retaining ring Turn adjusting ring until the spring is fully relaxed Hook wrench T106S Measure the overall spring length without a load Tighten the sp...

Page 73: ...ng the shock 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...

Page 74: ...ebar can be installed in the position most comfortable for the rider 10 14 Adjusting handlebar position x 401454 10 Remove screws Remove the handlebar clamps Remove the handlebar and lay it to one sid...

Page 75: ...E CHASSIS 73 Position the handlebar Info Make sure the cables and wiring are positioned correctly Position the handlebar clamps Mount and evenly tighten screws Guideline Screw handlebar clamp M8 20 Nm...

Page 76: ...vehicle on a firm and even surface 401942 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 77: ...B01281 10 Main work Push dust boot of both fork legs downwards Info The dust boots remove dust and coarse dirt particles from the inside fork tubes Over time dirt can penetrate behind the dust boots I...

Page 78: ...into their normal position Remove excess oil Finishing work Position the fork protector p 77 Remove the motorcycle from the lift stand p 74 11 4 Loosening the fork protection B01952 10 Remove screws a...

Page 79: ...fork leg Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 6 Checking the steering head bearing play Warning Danger of accidents Unstable vehicle handling from incorr...

Page 80: ...p 78 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...

Page 81: ...12 Nm 8 9 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid strains Fully tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Mount and tighten screw Guidel...

Page 82: ...back the seat and lift it off 11 9 Mounting the seat B01953 10 Hook slot of the seat onto screw press the rear downward and at the same time push it forward Push locking pin into lock housing and push...

Page 83: ...601783 10 Main work Remove screws Take off air filter box top 601784 10 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never operate the vehicle wit...

Page 84: ...lush against the air filter box along the entire sealing sur face If the air filter is not correctly mounted dust and dirt can enter the engine and cause damage Hook air filter box top into the front...

Page 85: ...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 86: ...idents Danger caused by incorrect chain tension If the chain is too taut the components of the secondary power transmission chain engine sprocket rear sprocket bearings in the transmission and in the...

Page 87: ...from the chain sliding guard and determine the chain tension Info The upper chain section must be taut Chain wear is not always even Repeat this measurement at different chain posi tions Chain tensio...

Page 88: ...bearings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme case...

Page 89: ...position relative to the reference marks The rear wheel is then correctly aligned Info The upper chain section must be taut Chain wear is not always even Repeat this measurement at different chain pos...

Page 90: ...per section of the chain with the specified weight Guideline Weight of chain wear measurement 15 kg 33 lb Measure distance of 18 chain links in the lower chain section Info Chain wear is not always ev...

Page 91: ...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 92: ...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 93: ...IS 91 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 94: ...ide Condition Number of teeth 44 teeth Insert nut in hole Position the chain guide Mount and tighten screws and Guideline Screw chain guide M6 8 Nm 5 9 lbf ft Condition Number of teeth 45 teeth Insert...

Page 95: ...and only and do not apply any force Do not make any adjustments while riding B01943 11 Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw When adjusting the clut...

Page 96: ...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 the...

Page 97: ...ON THE CHASSIS 95 11 21 Installing the engine guard G00755 10 Slide the engine guard into holders at the rear Position the engine guard Mount and tighten screws Guideline Remaining screws chassis M6 1...

Page 98: ...or recommended by KTM Service work and repairs must be performed properly Your authorized KTM workshop will be glad to help The ABS is a safety system that prevents locking of the wheels when driving...

Page 99: ...ar wheels differ greatly under extreme riding conditions for example when making wheelies or if the rear wheel spins This causes the ABS to switch off To reenable the ABS the vehicle must be stopped a...

Page 100: ...ar brake discs in several places to ensure that it conforms to measurement Info Wear reduces the thickness of the brake disc at the contact surface of the brake disc Brake discs wear limit Front 4 5 m...

Page 101: ...tem and do not continue riding Your autho rized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and...

Page 102: ...rake fluid comes into contact with 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 Chang...

Page 103: ...d tighten 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...

Page 104: ...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 eyes...

Page 105: ...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 106: ...c 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 th...

Page 107: ...ressure point B01958 12 Adjust the brake fluid level to level Guideline Measurement 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 193 Position the cover with the membrane Mount and tighten the screws Info C...

Page 108: ...ton when there is increased resistance when you activate the foot brake lever If the free travel does not meet specifications Adjust the basic position of the foot brake lever x p 106 12 9 Adjusting t...

Page 109: ...t brake lever has the necessary free travel Hold screws 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 lever p...

Page 110: ...g 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 Ch...

Page 111: ...e 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 p...

Page 112: ...ake disc The braking effect is greatly reduced and the brake discs are destroyed Check the brake linings regularly B01962 01 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 04 i...

Page 113: ...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 114: ...d the vehicle upright Remove screw cap with membrane 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 115: ...and mount the cotter pin Info Always change the brake linings in pairs Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point...

Page 116: ...and on to the brake disc in order to press back the brake pistons Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes Remove screw and pull wh...

Page 117: ...en the front wheel is removed Always lay the wheel down in such a way that the brake disc is not damaged B01966 10 Remove spacers 13 2 Installing the front wheel x Warning Danger of accidents Reduced...

Page 118: ...it and insert the wheel spindle The brake linings are positioned Mount and tighten screw Guideline Screw front wheel spindle M24x1 5 45 Nm 33 2 lbf ft Activate the hand brake lever multiple times unti...

Page 119: ...th the lift stand p 74 B01968 10 Main work Remove screw and pull wheel speed sensor out of the hole Press the brake caliper by hand on to the brake disc in order to press back the brake piston Remove...

Page 120: ...n the rear wheel is removed Always lay the wheel down in such a way that the brake disc is not damaged 13 4 Installing the rear wheel x Warning Danger of accidents Reduced braking efficiency due to oi...

Page 121: ...ring x Remove bushing Clean and grease the contact surfaces of the bushings of shaft seal ring Long life grease p 197 Clean and grease the thread of the wheel spindle and nut Long life grease p 197 In...

Page 122: ...ar wheel spindle M25x1 5 90 Nm 66 4 lbf ft Insert wheel speed sensor into the hole Mount and tighten screw Guideline Screw wheel speed sensor M6 6 Nm 4 4 lbf ft Operate the foot brake lever repeatedly...

Page 123: ...l rubber dampers in the rear hub B01973 10 Lay the rear wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub To check play hold the rear wheel tight and t...

Page 124: ...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 125: ...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 126: ...8 bar 26 psi Rear 1 8 bar 26 psi Tire air pressure with passenger fully loaded Front 2 2 bar 32 psi Rear 2 2 bar 32 psi If the tire pressure does not meet specifications Correct the tire pressure Mou...

Page 127: ...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 128: ...attery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rins...

Page 129: ...rical components and safety devices can be damaged The vehi cle is therefore no longer roadworthy 14 2 Installing the battery x B01975 11 Main work Insert the battery into the battery compartment with...

Page 130: ...ttery 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 Ke...

Page 131: ...r steadily The charging level and the method of charging are very important for the service life of the battery Rapid recharging with a high charging current shortens the battery s service life If the...

Page 132: ...ternator With this device you cannot overcharge the battery Info Never remove lid Charge the battery with a maximum of 10 of the capacity specified on the bat tery housing Switch off and disconnect th...

Page 133: ...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...

Page 134: ...eded Check the functioning of the electrical equipment Mount the protection covers Finishing work Mount the seat p 80 Set the clock p 32 14 5 Changing the ABS fuses Warning Fire hazard The electrical...

Page 135: ...1979 10 To change the fuse of the ABS hydraulic unit Take off protection cap and remove the fuse Insert a new fuse Fuse 58011109115 p 186 Mount the protection cap B01979 11 To change the fuse of the A...

Page 136: ...mers Info The fuse box containing the fuses of individual power consumers is located under the seat Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 80 B0198...

Page 137: ...amp Fuse 7 10 A for auxiliary equipment permanent positive Fuse 8 10 A for supplementary equipment accessories connected with ignition switch Fuse 9 10 A ABS Fuse 10 not used Fuse SPARE 10 A 15 A spar...

Page 138: ...ers Close the fuse box cover Finishing work Mount the seat p 80 14 7 Removing the headlight mask with the headlight Preparatory work Switch off all power consumers and switch off the engine B01982 10...

Page 139: ...connectors of turn signals and headlight Remove the headlight mask 14 8 Installing the headlight mask with the headlight 601794 11 Main work Connect the plug in connections of headlight and turn signa...

Page 140: ...ion line guides Mount and tighten screws Guideline Screw headlight mask M5 5 Nm 3 7 lbf ft Finishing work Check the headlight setting p 143 14 9 Changing the headlight bulb Note Damage to reflector Re...

Page 141: ...Take off protection cap of the headlight bulb 600611 10 Detach spring bar Remove headlight bulb Insert a new headlight bulb into the headlight housing Headlight H4 socket P43t p 186 Fix the headlight...

Page 142: ...rease 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...

Page 143: ...x9 5d p 186 Insert the bulb socket in the reflector Insert the protection cap Finishing work Install the headlight mask with the headlight p 137 Check the headlight setting p 143 14 11 Changing the tu...

Page 144: ...t counterclockwise by about 30 and take it out of the socket Info Do not touch the reflector with your fingers and keep it free from grease Press the new turn signal bulb carefully into the socket and...

Page 145: ...distance in front of the wall Guideline Distance 5 m 16 ft The rider with luggage and a passenger if applicable now sits down on the motorcycle Switch on the low beam Check the headlight setting For a...

Page 146: ...light and dark must be exactly on the lower mark for a motor cycle with a rider instructions on how to apply the mark Checking the headlight set ting Info Turn clockwise to increase the headlight rang...

Page 147: ...re 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 cooli...

Page 148: ...Keep coolant out of 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 Check antifreeze of coolant...

Page 149: ...pecifications 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 l...

Page 150: ...reach of children 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 The coolant level must be within th...

Page 151: ...Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immedi ately and contact a physician Immedi...

Page 152: ...must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with s...

Page 153: ...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 enclosed...

Page 154: ...Soft Set the adjusting wheel to position 1 Soft reduced homologated peak performance for better driveability Set the Map Select switch to Advanced Set the adjusting wheel to position 2 Advanced homolo...

Page 155: ...hift lever 0 0 0 A A 400692 10 Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the shift lever Distance between shift lever and upper edge of b...

Page 156: ...lever on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle components during th...

Page 157: ...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 158: ...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 159: ...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 filter...

Page 160: ...work Place a suitable container under the engine 100202 10 Main work Remove screws Remove the oil filter cover with the O ring Pull oil filter out of the oil filter housing Circlip pliers reverse 5101...

Page 161: ...ng 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 et...

Page 162: ...l Thoroughly 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...

Page 163: ...filter cover M5x16 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 0 0 1 1 401955 10 Main work Remove f...

Page 164: ...and check that it is oil tight Finishing work Install the engine guard p 95 Check the engine oil level p 155 17 8 Adding engine oil Info Too little engine oil or poor quality engine oil results in pre...

Page 165: ...xic 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 withou...

Page 166: ...uel cleaners 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 Avo...

Page 167: ...ke system to 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...

Page 168: ...ould enhance the corrosive effects of salt 401060 01 Clean the motorcycle p 164 Clean the brake system Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with c...

Page 169: ...18 CLEANING CARE 167 Clean the chain p 83...

Page 170: ...on 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 197 Refuel p 56 Clean the motorcycle p 164 Change the engine oil and filter...

Page 171: ...on Avoid running the engine for 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 Prepar...

Page 172: ...ine turns but does not start Operating error Carry out the start procedure p 47 Fuse 3 blown Change the fuses of individual power consumers p 134 Coupling of fuel hose connection not connected Reconne...

Page 173: ...tem Fill bleed the cooling system x p 150 FI warning lamp MIL lights flashes Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x N The idling speed indicator la...

Page 174: ...vidual power consumers p 134 Turn signal brake light and horn not functioning Fuse 5 blown Change the fuses of individual power consumers p 134 Time is not correctly displayed Fuse 1 blown Change the...

Page 175: ...arning lamp MIL 12 FI warning lamp MIL flashes 1x long 2x short Error level condition Engine coolant temperature sensor input signal too low Engine coolant temperature sensor input signal too high Bli...

Page 176: ...Error level condition Lambda sensor cylinder 1 sensor 1 circuit fault Blink code FI of warning lamp MIL 22 FI warning lamp MIL flashes 2x long 2x short Error level condition Gear position sensor circ...

Page 177: ...der 1 circuit fault Blink code FI of warning lamp MIL 37 FI warning lamp MIL flashes 3x long 7x short Error level condition Ignition coil 1 cylinder 1 circuit fault Blink code FI of warning lamp MIL 3...

Page 178: ...Error Blink code FI of warning lamp MIL 06 FI warning lamp MIL flashes briefly 6x Error level condition Throttle position sensor circuit A input signal too high Throttle position sensor circuit A inpu...

Page 179: ...lerator position sensor circuit B input signal too high Blink code FI of warning lamp MIL 87 FI warning lamp MIL flashes 8x long 7x short Error level condition Accelerator position sensor circuit A an...

Page 180: ...nk code FI of warning lamp MIL 94 FI warning lamp MIL flashes 9x long 4x short Error level condition DBW stop function system error stop function A system error Blink code FI of warning lamp MIL 95 FI...

Page 181: ...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 Pistons F...

Page 182: ...ing permanent circulation of coolant by water pump Starting aid Electric starter automatic decompressor 22 2 Engine tightening torques Screw membrane fixation M3 2 Nm 1 5 lbf ft Loctite 243 Hose clamp...

Page 183: ...t M6 10 Nm 7 4 lbf ft Loctite 243 Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch slave cylinder M6x20 10 Nm 7 4 lbf ft Loctite 243 Screw clutch slave cylinder M6x35 10 Nm 7 4 lbf ft Screw cranksh...

Page 184: ...ew plug crankshaft clamp M8 20 Nm 14 8 lbf ft Stud exhaust flange M8 10 Nm 7 4 lbf ft Loctite 243 Cylinder head screw M10 Tightening sequence Tighten diagonally beginning with the rear screw on the ti...

Page 185: ...e 243 Engine case stud M16x1 5 25 Nm 18 4 lbf ft Loctite 243 Rotor nut M18x1 5 100 Nm 73 8 lbf ft Nut engine sprocket M20x1 5 80 Nm 59 lbf ft Loctite 243 Nut inner clutch hub M20x1 5 100 Nm 73 8 lbf f...

Page 186: ...Chassis Frame Lattice frame made of chrome molybdenum steel tubing powder coated Fork WP Suspension 4860 MXTA SPLIT Shock absorber WP Suspension 4618 with Pro Lever deflector Suspension travel Front 2...

Page 187: ...offroad single rider Front 1 5 bar 22 psi Rear 1 5 bar 22 psi Secondary drive ratio 15 45 Chain 5 8 x 1 4 X ring Steering head angle 63 Wheelbase 1 504 15 mm 59 21 0 59 in Seat height unloaded 910 mm...

Page 188: ...09115 15 A Fuse 58011109125 25 A Fuse 58011109130 30 A Fuse 75011088015 15 A Fuse 75011088010 10 A Headlight H4 socket P43t 12 V 60 55 W Parking light W5W socket W2 1x9 5d 12 V 5 W Instrument lights a...

Page 189: ...ktm com 22 7 Fork Fork part number 14 18 8N 10 Fork WP Suspension 4860 MXTA SPLIT Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfo...

Page 190: ...sion 4618 with Pro Lever deflector Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Compression damping low speed Comfort 20 clicks Standard 15 clicks...

Page 191: ...Nm 2 2 lbf ft Screw side cover on spoiler EJOT 1 Nm 0 7 lbf ft Screw side stand switch EJOT 2 Nm 1 5 lbf ft Screw SLS valve EJOT 2 Nm 1 5 lbf ft Fitting side stand switch M4 2 Nm 1 5 lbf ft Spoke nip...

Page 192: ...Nm 7 4 lbf ft Screw connection foot brake cylinder M6 10 Nm 7 4 lbf ft Screw ABS control unit M6 5 Nm 3 7 lbf ft Screw air filter box top M6 2 Nm 1 5 lbf ft Screw ball joint of push rod on foot brake...

Page 193: ...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 foot brake lever M8 25 Nm 18 4 lbf ft Loctite 243 Screw fork stub M8 15 Nm 11 1...

Page 194: ...rew 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 Loctite 243 Screw side stand M10 35 Nm 25 8...

Page 195: ...astrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant even in countries with high temperatures Using inferior antifreeze can result in corrosi...

Page 196: ...ntainer and that possess the corresponding properties Synthetic engine oil Recommended supplier Motorex Cross Power 4T Engine oil SAE 10W 50 Standard classification JASO T903 MA p 199 SAE p 199 SAE 10...

Page 197: ...draulic oil that complies with the specified standard see specifications on the container and that possesses the corre sponding properties Recommended supplier Motorex Hydraulic Fluid 75 Shock absorbe...

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: ...orex Chain Clean Fuel additive Recommended supplier Motorex Fuel Stabilizer Long life grease Recommended supplier Motorex Bike Grease 2000 Motorcycle cleaner Recommended supplier Motorex Moto Clean Of...

Page 200: ...ex Moto Polish Shine Preserving materials for paints metal and rubber Recommended supplier Motorex Moto Protect Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommend...

Page 201: ...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 202: ...p brake fluid of front brake 100 Brake fluid level checking the brake fluid level of front brake 99 rear brake checking 107 Brake linings front brake changing 102 front brake checking 101 rear brake c...

Page 203: ...P 2 display setting resetting 34 TRIP F display 35 Coolant draining 149 Coolant level checking 145 147 Cooling system 145 filling bleeding 150 Customer service 14 E Electric starter button 26 Emergenc...

Page 204: ...s ABS changing 132 H Hand brake lever 23 basic position adjusting 97 Handlebar position 72 adjusting 72 Handrails 38 Headlight light range adjusting 143 Headlight bulb changing 138 Headlight mask with...

Page 205: ...ng 87 Rear wheel installing 118 removing 117 Riding 49 starting off 49 Riding sag adjusting 71 S Safe operation 10 Seat mounting 80 removing 80 Seat release 38 Service 13 Service schedule 59 61 Shift...

Page 206: ...ctrical system 186 engine 179 engine tightening torques 180 fork 187 shock absorber 188 tires 187 Throttle grip 24 Tire air pressure checking 123 Tire condition checking 122 Transport 55 Troubleshooti...

Page 207: ...3213101en 3213101en 12 2013 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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