KTM 690 Enduro R Owner'S Manual Download | Manualshive

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MAINTENANCE WORK ON CHASSIS AND ENGINE

78

9.25

Adjusting the chain tension

Warning

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 and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture
or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or
the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if necessary.

–

Check the chain tension. (

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Summary of Contents for 690 Enduro R

Page 1: ...OWNER S MANUAL 2010 690 Enduro R USA Art no 3211512en ...

Page 2: ......

Page 3: ...viations resulting from continuing devel opment and design of our motorcycles cannot however be completely excluded 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 without prior notice and without specifying reasons to adapt these to local conditions a...

Page 4: ...d only with the express written permission of the copyright owner ISO 9001 12 100 6061 According to the international quality management standard ISO 9001 KTM uses quality assurance processes that lead to the maximum possible quality of the products Issued by TÜV Management Service KTM Sportmotorcycle AG 5230 Mattighofen Austria ...

Page 5: ...ion instrument display 31 Combination instrument speedometer 32 Setting kilometers or miles 32 Combination instrument time 33 Setting the clock 33 Combination instrument display ODO 34 Combination instrument setting resetting TRIP 1 34 Combination instrument setting resetting TRIP 2 35 Combination instrument TRIP F display 36 Combination instrument coolant temperature indicator 36 Opening filler c...

Page 6: ... handlebar position x 74 Checking the chain for dirt 75 Cleaning the chain 75 Checking the chain tension 77 Adjusting the chain tension 78 Checking the chain rear sprocket and engine sprocket 80 Adjusting chain guide x 83 Checking the brake discs 83 Checking the free travel of the hand brake lever 84 Adjusting the free travel of the hand brake lever 85 Checking the front brake fluid level 86 Addin...

Page 7: ...ay in the throttle cable x 139 Removing the engine guard 139 Installing the engine guard 140 Checking the engine oil level 140 Changing the engine oil and filter cleaning the oil screens x 141 Draining the engine oil x 141 Removing the oil filter x 142 Installing the oil filter x 144 Cleaning the oil screens x 144 Filling up with engine oil x 146 Adding engine oil 147 TROUBLESHOOTING 149 FLASHING ...

Page 8: ...nd 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 below Specific name Identi...

Page 9: ...y muddy or wet roads can lead to above average wear of components such as the transmission train or the brakes For this reason it may be necessary to service or replace worn parts before the limit specified in the ser vice schedule is reached Pay careful attention to the prescribed running in period inspection and maintenance intervals If you observe these exactly you will ensure a much longer ser...

Page 10: ...ng mounter 59029019000 During assembly non reusable parts e g self locking screws and nuts seals and seal rings O rings pins lock washers must be replaced by new parts If a thread lock e g Loctite is used for screw connections be sure to comply with the manufacturer s specific instructions on its usage Parts that you want to reuse following repairs and servicing should be cleaned and checked for d...

Page 11: ...naturally hope that you will be able to enjoy it to the fullest However it is a potential problem for the environment and can lead to conflicts with other persons But if you use your motorcycle responsibly you can ensure that such problems and conflicts do not have to occur To protect the future of motorcycle sport make sure that you use your motorcycle legally display environmental consciousness ...

Page 12: ...IMPORTANT INFORMATION 10 2 1 Overview of warning labels 800103 10 ...

Page 13: ...da 2 Type label USA 3 Information emission control 4 Information noise emission 5 Information suspension setting 6 Information chain tension 7 Information fuel evaporation system 8 Information putting into operation 800110 01 Type label Canada ...

Page 14: ...IMPORTANT INFORMATION 12 B00112 01 Type label USA B00099 01 Information emission control ...

Page 15: ...IMPORTANT INFORMATION 13 B00100 01 Information noise emission B00111 01 Information suspension setting ...

Page 16: ...IMPORTANT INFORMATION 14 100338 01 Information chain tension 100336 01 Information fuel evaporation system 700210 01 Information putting into operation ...

Page 17: ...y and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken Note Identifies a danger that will lead to considerable machine and material ...

Page 18: ...an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remady campaign However NHTSA cannot become involved in individual problems between you your dealer or KTM North America Inc To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 888 327 4236 or visit the website www nhtsa dot gov or write to NHTSA Headquarters 1200 N...

Page 19: ...her components which conducts exhaust gases 2 Removal or puncturing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving part of the vehicle or parts of the exhaust or intake system with parts other than those specified by the manu facturer Warning operating noise This product should be checked for repair or replacement if the motorcycle noise has increased signific...

Page 20: ...VIEW OF VEHICLE 18 3 1 View of vehicle front left side 800106 10 ...

Page 21: ...VIEW OF VEHICLE 19 1 Hand brake lever 2 Clutch lever 3 Handrail 4 Filler cap 5 Seat 6 Front brake caliper 7 Shift lever 8 Engine number 9 Side stand 10 Footrest 11 Seat release strap ...

Page 22: ...VIEW OF VEHICLE 20 3 2 View of vehicle rear right 800107 10 ...

Page 23: ...ht switch flasher switch horn button 4 Combination instrument 5 Emergency OFF switch electric starter button 6 Throttle grip 7 Chassis number 8 Brake caliper rear 9 Passenger footrest 10 Shock absorber rebound damping 11 Foot brake pedal 12 Level viewer engine oil ...

Page 24: ...ON OF SERIAL NUMBERS 22 4 1 Chassis number 100217 10 The chassis number is stamped on the steering head on the right 4 2 Type label 100218 10 Type label is located on the upper right frame tube below the seat ...

Page 25: ...9 10 The 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 4 4 Engine number 100211 10 The engine number is stamped on the left side of the engine under the engine sprocket ...

Page 26: ... NUMBERS 24 4 5 Fork part number 800072 10 The fork part number is stamped on the inner side of the fork stub 4 6 Shock absorber part number 100216 10 The shock absorber part number is on the right of the shock absorber ...

Page 27: ...h lever is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 5 2 Hand brake lever 100220 10 The hand break lever is fitted on the right side of the handlebar The hand brake lever operates the front brake ...

Page 28: ...switched on 5 4 Turn signal switch 100223 10 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 left The turn signal switch returns automatically to the central position after use Turn signal light right on Turn signal switch pressed to the right The turn signal switch returns automatically ...

Page 29: ...operated in this position 5 6 Emergency OFF switch 100225 10 The emergency OFF switch is fitted on the right side of the handlebar Possible states Emergency OFF switch off In this position the ignition circuit is inter rupted a running engine stops and the engine cannot be started Emergency OFF switch on This position is necessary for operation as the ignition circuit is closed ...

Page 30: ...n steering lock 600825 01 The ignition steering lock is located in front of the seat Possible states Ignition OFF In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start The ignition key can be removed Ignition ON In this position the ignition circuit is closed and the engine can be started Steering locked In this position the ignition ci...

Page 31: ... function areas Function buttons Indicator lamps Display 5 10 Combination instrument function buttons 800083 11 You can change the display mode with the M button Possible display modes are distance traveled Odo trip master 1 Trip 1 and trip mas ter 2 Trip 2 Press the S button to reset the trip master 1 function Trip 1 and trip master 2 function Trip 2 to 0 00 ...

Page 32: ... signal light is switched on Fuel level warning lamp lights up orange Fuel level has reached the reserve mark Display switched to Trip F Temperature warning lamp lights up red Coolant has reached a critical value High beam indicator lamp lights up blue High beam is switched on The idle speed indicator lamp lights up green The transmission is switched to idle FI warning lamp MIL lights up flashes o...

Page 33: ...y segments light up for a second as a function test 800083 14 LEnGth Following the display function test the wheel circumference LEnGth is shown for one sec ond Info 2205 mm equals the circumference of the 21 front wheel with a series production tire The display then changes to the last selected mode ...

Page 34: ...The speed is shown in kilometers per hour km h or in miles per hour mph 5 14 Setting kilometers or miles Info If you change the unit the value is retained and converted accordingly Making the setting according to the country Condition The motorcycle is stationary ...

Page 35: ...tton pressed until the display mode changes from km h to mph or from mph to km h Guideline Activation duration of M button 10 s 5 15 Combination instrument time 800083 17 The time is shown in area of the display Info The time must be reset after the battery is reconnected or when the fuse is changed 5 16 Setting the clock Condition The motorcycle is stationary ...

Page 36: ...sed simultaneously The time is set 5 17 Combination instrument display ODO 800083 18 In the Odo display mode the total distance traveled is shown in kilometers or miles Info This value is retained even if the battery is disconnected and or the fuse blows 5 18 Combination instrument setting resetting TRIP 1 Info The TRIP 1 trip counter runs constantly and counts up to 999 9 The trip counter can be ...

Page 37: ...ting TRIP 2 Info The TRIP 2 trip counter runs constantly and counts up to 999 9 The trip counter can be used to measure the distance covered during trips or between two refueling stops After the value 999 9 is reached the trip counter starts at 0 0 again 800083 20 Switch on the ignition by turning the ignition key to position ON Press the M button repeatedly until the Trip 2 mode is active Keep th...

Page 38: ...to the Trip F display the fuel warning light switches on 5 21 Combination instrument coolant temperature indicator 800085 10 The temperature display consists of 8 bars The more bars that light up the hotter the coolant When the upper bar lights up all bars in the display begin to flash and the tem perature warning lamp lights up Possible states Engine cold No bars light up Engine warm Four bars li...

Page 39: ...nsert the ignition key Turn the ignition key 90 counterclockwise and remove the filler cap Info The filler cap has a tank air vent system 5 23 Closing filler cap 100228 01 Put the filler cap back on and turn the ignition key 90 clockwise Remove the ignition key and fold down the cover ...

Page 40: ...drails 100229 10 The handrails are used for moving the motorcycle around When you have a passenger the passenger can hold on the handrails during the journey 5 25 Seat release 100230 10 The seat can be released using strap ...

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 5 27 Shift lever 100215 10 The shift lever is mounted on the left side of the engine ...

Page 42: ...s can be seen in the photograph The neutral or idle position is between the first and second gears 5 28 Foot brake lever 100232 10 Foot brake lever is located in front of the right footrest The rear brake is engaged with the foot brake lever ...

Page 43: ...ic starter system see the riding instruc tions Possible states Side stand folded out The vehicle can be supported on the side stand The safety electric starter system is active Side stand folded in This position is mandatory for all journeys The safety electric starter system is inactive ...

Page 44: ...fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable 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 accidents Reduced road grip with new tires New tires have a smooth rolling surfac...

Page 45: ... 85 Adjust the basic position of the foot brake lever x p 93 Get used to handling the motorcycle on a suitable piece of land before making a longer trip Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle Do not make any offroad trips that over stress your ability and experience Hold the handlebar firmly with both hands and keep your feet on th...

Page 46: ...ling characteristics at high speed Adapt your speed according to your payload Ride more slowly if your motorcycle is loaded with cases or other baggage Maximum speed with baggage 130 km h 80 8 mph Warning Danger of accidents Risk of breakage of suitcase system If you have fitted suitcases on your motorcycle read the manufacturer s specifications concerning the maximum payload Warning Danger of acc...

Page 47: ...ch a way that it cannot be burned or singed by the hot exhaust system If you carry any baggage make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribu tion between the front and rear wheels Do not exceed the overall maximum permitted weight and the axle loads Guideline Maximum permissible overall weight 350 kg 772 lb Maximum permissible front ...

Page 48: ...he chain tension p 77 Clean the chain p 75 Check the tire condition p 107 Check the tire air pressure p 108 Check the front brake fluid level p 86 Check the rear brake fluid level p 94 Check the front brake linings p 88 Check the rear brake linings p 97 Check brake system function Check the coolant level p 132 Check that all controls are correctly adjusted and free to move Check that the electrica...

Page 49: ...nd 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 life of the engine Always warm up the engine at low engine speeds B00103 10 Turn the emergency OFF switch to the position Switch on the ignition by turning the ignition key to position ON After you s...

Page 50: ... a gear is engaged If the side stand is folded out and you shift into gear and release the clutch the engine stops Take the weight off the side stand and swing it back up with your foot as far as it will go 7 3 Starting up Pull the clutch lever engage 1st gear release the clutch lever slowly and simultaneously open the throttle carefully 7 4 Shifting riding Warning Danger of accidents Abrupt load ...

Page 51: ...ngers in your country Warning Danger of accidents Danger of accidents caused by dangerous driving Observe the traffic regulations and ride defensively and with foresight in order to recognize danger as early as possible Warning Danger of accidents Reduced road grip with cold tires On every journey take the first miles carefully at moderate speed until the tires reach operating temperature and opti...

Page 52: ...usual before putting it into operation Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear Note Engine failure Overheating of engine If the coolant temperature warning lamp lights up stop and switch off the engine Allow the engine to co...

Page 53: ...onsid 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 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 If the engine stalls e g at a crossroad...

Page 54: ...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 authorized KTM workshop will be glad to help Warning Danger of accidents Failure of brake system If the foot brake lever is not released the brake linings drag permanently The rear brake can fail due to overhe...

Page 55: ...s but do not overstress the engine In this way you have to brake far less and the brakes do not overheat 7 6 Stopping parking Warning Risk of misappropriation Usage by unauthorized persons Never leave the 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 Danger of burns Some vehi...

Page 56: ...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 intended for emergencies only Park the motorcycle on a firm surface Swing the side stand forward with your foot as far as it will go and lean the vehicle on it Lock the steering by turning the handlebar fully to the left pressing down th...

Page 57: ...e into contact with fuel Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Info This motorcycle is equipped with a regulated catalyst Leaded fuel will destroy the catalyst You should therefore use unleaded fuel only 400405 10 Switch off engine Open the filler cap p 37 Fill the fuel ta...

Page 58: ...ress the S button for two seconds The fuel level warning lamp switches off Trip F is set to 0 0 and appears in the previous display mode Info If you do not press the S button the reset takes place automatically after about three minutes ...

Page 59: ...Check the free travel of the foot brake lever p 93 Lubricate the linkage of the rear wheel suspension x Check that the shock absorber and fork are leak tight If necessary and depending on use service the fork and shock absorber Check the swingarm bearing x Check the wheel bearing for play x Check the tire condition p 107 Check the tire air pressure p 108 Check the spoke tension p 109 Check for rim...

Page 60: ...e undamaged routed without sharp bends and set correctly Change the air filter Clean the air filter box x Check rectify the fluid level of the hydraulic clutch p 137 Check the screws and nuts for tightness x Change the coolant x Change the front brake fluid x Change the rear brake fluid x Check the clutch x Check the headlight setting p 126 Check that the radiator fan is functioning properly x Fin...

Page 61: ...SERVICE SCHEDULE 59 K75A Every 7 500 km 4 660 mi or annually K150A Every 15 000 km 9 321 mi or every 2 years K300A Every 30 000 km 18 641 mi or every 4 years ...

Page 62: ...p the motorcycle on the underride guard underneath the engine The wheels must no longer touch the ground Secure the motorcycle against falling over 9 2 Removing the motorcycle from the work stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Remove the motorcycle from the work stand and rest it on its side stand Remove the w...

Page 63: ...is of your own personal chassis adaptation Do not change the adjustments at random or by more than 40 since otherwise the riding characteristics could deteriorate particularly at high speeds 9 4 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior 800074 10 Remove protection covers Turn adjusting screws clockwise until they st...

Page 64: ...to reduce damping Mount protection covers 9 5 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork rebound behavior 800090 10 Turn adjusting screws clockwise until they stop Info The adjusting screws are located at the top end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise by the number of clicks corresponding to t...

Page 65: ...d high speed refer to the movement of the shock absorber during compression and not the riding speed of the motorcycle Changes in the settings in the low speed range have an impact on the high speed range and vice versa 9 7 Adjusting the low speed compression damping of the shock absorber Danger Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled wi...

Page 66: ...andard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 9 8 Adjusting the high speed compression damping of the shock absorber Danger Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM wor...

Page 67: ...ssion 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 damping 9 9 Adjusting the rebound damping of the shock absorber Danger Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Y...

Page 68: ... clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 9 10 Measuring the unloaded rear wheel sag Jack up the motorcycle p 60 0 0 A A 400220 10 Measure the distance as vertically as possible between the rear axle and a fixed point for example a mark on the side cover Make a note of the value as measurement R...

Page 69: ... to help you by holding the motorcycle upright Measure the distance between the rear axle and the fixed point again Make a note of the value as measurement Info The static sag is the difference between measurements and Check the static sag Static sag 25 mm 0 98 in If the static sag is less or more than the specified value Adjust the spring preload of the shock absorber x p 68 ...

Page 70: ...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 70 80 mm 2 76 3 15 in If the riding sag differs from the specified measurement Adjust the riding sag x 9 13 Adjusting the spring preload of the shock absorber x Danger Danger of accident...

Page 71: ...er clean it thoroughly 700541 01 Loosen locking ring Turn adjusting ring until the spring is no longer under tension Hook wrench T106S Measure the overall spring length when not under tension Tension the spring by turning the adjusting ring to the prescribed value Guideline Spring preload 20 mm 0 79 in Tighten locking ring Install the shock absorber x 9 14 Bleeding the fork legs Lean the motorcycl...

Page 72: ... Push dust boot of both fork legs downwards Info The dust boots should remove dust and coarse dirt particles from the fork tubes Over time dirt can penetrate behind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and cle...

Page 73: ...ush the fork protection downwards Remove the screws on the right fork leg Push the fork protection downwards 9 17 Positioning the fork protection 800092 11 Position the fork protection on the left fork leg Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line and wiring harness Put the clamp on mount and tighten screws Position the fork protection ...

Page 74: ...p the motorcycle p 60 100298 10 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 If there is noticeable play present Adjust the play of the steering head bearing x p 73 Move the handlebar to and fro over the entire steering range The handlebar must be able to move easily over the ent...

Page 75: ... Guideline Screw top steering head M20x1 5 10 Nm 7 4 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 Guideline Screw steering stem M8 20 Nm 14 8 lbf ft Loctite 243 Check the steering head bearing play p 72 Remove the motorcycle from the work stand p 60 ...

Page 76: ...andlebar can be installed in the position most comfortable for the rider 9 21 Adjusting handlebar position x 0 0 2 2 0 0 1 1 400271 10 Remove the four screws Remove the handlebar clamp 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 two screws Remove the handlebar support Place the ...

Page 77: ... tighten the four screws Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Loctite 243 9 22 Checking the chain for dirt 400678 01 Check the chain for heavy soiling If the chain is very dirty Clean the chain p 75 9 23 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 ...

Page 78: ...ronmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info The service life of the chain depends largely on its maintenance 400725 01 Clean the chain regularly Rinse off loose dirt with a soft jet of water Remove old grease remains with chain cleaner Chain cleaner p 180 After d...

Page 79: ... other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check the chain tension and correct if necessary 100249 10 Lean the motorcycle on the side stand Shift gear to neutral Push the chain upward at a distance from the chain sliding guard and determine the chain tension Info The upper chain section must be taut Chain...

Page 80: ...ngine sprocket rear sprocket bearings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check the chain tension and correct if necessar...

Page 81: ...rence marks The rear wheel is then correctly aligned Info The upper chain section must be taut Chain wear is not always even so you should check this setting at different chain positions Tighten nuts Make sure that the chain adjusters are installed correctly on adjusting screws Tighten nut Guideline Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Info The wide adjustment range of the chain adjust...

Page 82: ...sprocket and engine sprocket 100132 10 Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Replace the rear sprocket or engine sprocket x Info The engine sprocket rear sprocket and chain should always be replaced together ...

Page 83: ...Maximum distance at the longest chain section 272 mm 10 71 in If distance is greater than the specified measurement Replace the chain x Info When the chain is replaced the rear sprocket and engine sprocket should also be changed New chains wear out faster on old worn sprockets For safety reasons the chain has no chain joint 400925 01 Check the chain sliding guard for wear If the chain sliding guar...

Page 84: ...chassis M6 10 Nm 7 4 lbf ft 302112 10 Check the chain guide for wear If the chain guide is worn Change the chain guide x 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 ...

Page 85: ...ws and Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Condition Number of teeth 45 teeth Insert nut in hole Position the chain guide Mount and tighten screws and Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 9 28 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 wo...

Page 86: ...disc thickness is less than the specified value Replace the brake disc Check the front and rear brake discs for damage cracks and deformation If damage cracks or deformation are visible on the brake disc Replace the brake disc 9 29 Checking the free travel of the hand brake lever Warning Danger of accidents Brake system failure If there is no free travel on the hand brake lever pressure builds up ...

Page 87: ...brake lever 100252 10 Check the free travel of the hand brake lever p 84 Adjust the free travel of the hand brake lever with adjusting screw Info Turn the adjusting screw clockwise to reduce free travel The pressure point moves away from the handlebar Turn the adjusting screw counterclockwise to increase free travel The pressure point moves towards the handlebar The range of adjustment is limited ...

Page 88: ...the brake fluid of the front and rear brakes according to the service schedule Your authorized KTM workshop will be glad to help 100253 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Check the brake fluid level in the viewer If the brake fluid level is below the MIN mark Add front brake fluid x p 86 9 32 Adding front brake fluid x Warning Danger of accidents Fa...

Page 89: ...nt and rear brakes according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not d...

Page 90: ...water 9 33 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help Note Danger of accidents Reduced braking efficiency caused by damaged brake discs If the brake linings are not changed in time the steel brake lining carriers grind on the brake disc T...

Page 91: ...re Maintenance work and 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 and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediate...

Page 92: ...differ considerably from the original KTM brake lin ings If brake linings are used that differ from the originals there is no guarantee that they comply with the original license The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid ...

Page 93: ...the brake disc by hand in order to push back the brake pis tons Make sure that no brake fluid escapes from the brake fluid reservoir If it does clean it up Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes 400418 11 Remove the safety clip knock the pin out to the right and remove the brake lin ings Clean brake caliper and brake caliper su...

Page 94: ...s insert the bolt and mount the split pin Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a pressure point 100254 12 Add brake fluid level to Guideline Measurement of 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 176 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid immediately with water ...

Page 95: ...iston and check free travel Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Info You will know that contact has been made with the foot brake cylinder piston when there is increased resistance when you activate the foot brake lever If the free travel does not meet specifications Adjust the basic position of the foot brake lever x p 93 9 36 Adjusting the basic position of the foot brak...

Page 96: ... so that the foot brake lever has the necessary free travel Hold screws in place and tighten the nuts Guideline Nut foot brake cylinder screw M6 10 Nm 7 4 lbf ft Check the free travel of the foot brake lever p 93 Tighten nut 9 37 Checking rear brake fluid level 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 ...

Page 97: ... fluid x p 95 9 38 Adding 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 Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid...

Page 98: ...d be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 100259 10 Stand the vehicle upright Remove screw cap with the washer and me...

Page 99: ...on the brake disc The braking effect is greatly reduced and the brake discs are rendered unserviceable Check the brake linings regularly 100260 10 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings x p 97 Check the brake linings for damage and cracking If there is wear or tearing Change the rear...

Page 100: ... 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 available from accessory suppliers are often not tested and approved for use on KTM vehicles The construction and friction factor of the brake linings and therefore the brake power can differ considera...

Page 101: ...r 100259 10 Stand the vehicle upright Remove the screw cap with the membrane Press the brake caliper onto the brake disc by hand in order to push back the brake pis tons Make sure that no brake fluid escapes from the brake fluid reservoir If it does clean it up Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes 100288 10 Remove the safety c...

Page 102: ... pads insert the bolt and mount the split pin Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a pressure point Add brake fluid to the MAX mark Brake fluid DOT 4 DOT 5 1 p 176 Mount the screw cap with the membrane Info Clean up overflowed or spilt brake fluid immediately with water 9 41 Removing the front wheel x Jack up the motorcycle p 60 ...

Page 103: ...er to press back the brake pistons 800079 10 Remove screw Loosen screw 100263 10 Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork Info Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not damaged ...

Page 104: ...l or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary 800080 11 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Replace the wheel bearing x Clean and grease the shaft seal rings and bearing surface of the distance bush ings Long life grease p 181 Insert the spacers ...

Page 105: ...re lying correctly on the brake disc Remove the motorcycle from the work stand p 60 Pull the front wheel brake and push down hard on the fork several times to align the fork legs Tighten screws Guideline Screw fork stub M8 15 Nm 11 1 lbf ft 9 43 Removing rear wheel x Jack up the motorcycle p 60 100267 10 Press the brake caliper by hand on to the brake disc in order to press back the brake piston R...

Page 106: ... of the swing arm Info Do not operate the foot brake when the rear wheel is removed 9 44 Installing the rear wheel x Warning Danger of accidents Reduced braking efficiency 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 No braking effect when operating the rear brake After instal...

Page 107: ...the swingarm and bring the brake disc on the brake caliper into contact 100270 10 Push the rear wheel forward as far as possible and lay the chain on the rear sprocket Install the wheel spindle the chain adjusters and the nut Guideline In order that the rear wheel is correctly aligned the markings on the left and right chain adjusters must be in the same position relative to the reference marks In...

Page 108: ... wheel x p 103 100271 10 Check bearing If the bearing is damaged or worn Replace the bearings x Check rubber dampers of the rear hub for damage and wear If the rubber dampers of the rear hub are damaged or worn Change all rubber dampers in the rear hub 100272 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 re...

Page 109: ...g Danger of accidents Uncontrollable 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 accidents Reduced road grip with new tires New tires have a smooth rolling surface and therefore cannot provide full road grip The entire rolling surface must be rough ened in t...

Page 110: ...the age of 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 and last two digits refer to the year of manufacture KTM recommends that the tires are changed regardless of the actual wear at the latest after five years If a tire is more than five years o...

Page 111: ... solo Front 1 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 Mount the dust cap 9 48 Checking the spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that the spoke tension is correct Your authorized KTM w...

Page 112: ... 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 frequencies from individual spokes of the same length and thickness this is an indication of different spoke tensions You should hear a high note If the spoke tensions differ Correct the spoke tension x 9 49 Removing the seat 100230 10 Pull on strap an...

Page 113: ...ing the battery x Warning Risk of injury Battery acid and battery gases cause serious cauterization 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 contact rinse with large amounts of water If battery ac...

Page 114: ...e battery rack Info Never operate the motorcycle with a discharged battery or without a battery In both cases electrical components and safety devices can be damaged The vehi cle is therefore no longer roadworthy 9 52 Installing the battery x 100277 11 Slide the battery into the battery rack Info The battery terminals must be at the rear Attach the positive cable and mount positive terminal cover ...

Page 115: ...n contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Warning Environmental hazard Battery parts and acid are harmful to the environment Do not discard batteries with the household trash Dispose of a defective battery in an environmentally compatible manner Give the battery to your KTM dealer or to a recycling cen...

Page 116: ...voltage and charging time 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 the battery is left in a discharged state for an extended period it will become over discharged and sulfate destroying the battery The battery is maintenance free which means...

Page 117: ... Never remove lid Charge the battery with a maximum of 10 of the capacity specified on the bat tery housing Switch off and disconnect the charger after charging Guideline The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the motorcycle is not in use 3 months Install the battery x p 112 9 54 Changing the main fuse Warning Fire hazard The electr...

Page 118: ...onsumers and switch off the engine Remove the seat p 110 600604 10 Remove protection covers 600605 10 Use a needle nose plier to remove a defective main fuse Insert the new main fuse Fuse 58011109130 p 168 Info A reserve fuse is located in the starter relay Check that the electrical equipment is functioning properly Mount the protection covers Mount the seat p 111 Set the clock p 33 ...

Page 119: ... 55 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat Switch off all power consumers and the engine Remove the seat p 110 600604 11 Open fuse box cover ...

Page 120: ...A high beam low beam parking light tail light license plate lamp Fuse 8 10A for accessories accessories connected with ignition switch Fuse 9 10A for accessories permanent positive Fuse 10 not used Fuse SPARE 10A 15A spare fuses Info A defective fuse can be identified by the burned out fuse wire Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses Use only fuse...

Page 121: ...r consumer is functioning properly Close the fuse box cover Mount the seat p 111 9 56 Adjusting the engine characteristic Switch off the ignition by turning the ignition key to position OFF Remove the seat p 110 100237 10 Pull the Map Select switch and holder upward off of the retaining bracket Pull the Map Select switch out of the holder ...

Page 122: ...et 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 Select switch to poor fuel quality Set the adjusting wheel to position 0 Poor fuel quality homologated performance is reduced in accordance with the fuel quality use for no more than 1 tank of fuel Position the Map Select switch in the ...

Page 123: ... ENGINE 121 800097 10 Remove screw and take off the clamp Release rubber band Slide the headlight mask upward and tilt it forward 800102 10 Disconnect the electrical plug in connection and remove the headlight mask with the headlight ...

Page 124: ...MAINTENANCE WORK ON CHASSIS AND ENGINE 122 9 58 Installing the headlight mask with the headlight 800102 11 Connect the electrical plug in connection ...

Page 125: ...nder Position the brake line and wiring harness Position the clamp and mount and tighten screw 9 59 Changing the headlight bulb Note Damage to reflector Reduced luminance Grease 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 Remove the headlight mask with the headlight p 120 ...

Page 126: ...d p 168 Insert the holder into the headlight housing and fix it by turning it approx 30 clock wise Replace the rubber cap Attach the connector Install the headlight mask with the headlight p 122 9 60 Changing the parking light bulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease...

Page 127: ...nce Grease 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 100160 10 Remove the screw on the rear of the turn signa housing Tilt headlamp diffuser forward carefully and take it off Press the turn signal bulb carefully into the socket turn it counterclockwise by about 30 and take it out of the socket Info Do not ...

Page 128: ...wall and make a mark at the height of the center of the low beam headlight Make another mark at a distance under the first mark Guideline Distance 5 cm 2 in Position the vehicle vertically at a distance in front of the wall Guideline Distance 5 m 16 ft Check the headlight setting The boundary between light and dark must be exactly on the lower mark for a vehicle with a rider If the boundary betwee...

Page 129: ...deline For a motorcycle with rider the light dark boundary must be exactly on the lower mark made in Checking headlight adjustment Info If you have a heavy payload you will need to correct the headlight range Tighten screw 9 64 Removing the air filter x Remove the seat p 110 100285 10 Remove screws Remove filter box top ...

Page 130: ... into the engine and result in increased wear Remove air filter 9 65 Installing the air filter x 100287 10 Clean the air filter box Mount air filter Info The air filter must lie flush against the air filter box along the entire sealing sur face If the air filter is not correctly mounted dust and dirt can penetrate into the engine and can cause damage Hook filter box top into the front of the air f...

Page 131: ...in the engine forces the coolant to flow The pressure in the cooling system resulting from heat is regulated by a valve in the radi ator cap The heat expansion causes the surplus coolant to flow into the compensating tank When the temperature falls this surplus coolant is sucked back into the cooling system This permits the specified coolant temperature without causing any malfunctions 125 C 257 F...

Page 132: ...remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and 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 d...

Page 133: ...45 C 13 49 F If the antifreeze of the coolant does not meet specifications Correct the antifreeze of the coolant Check the coolant level in the compensating tank The coolant level must be within the range shown in the figure If the coolant level does not meet specifications Correct the coolant level Alternative 1 Coolant p 176 Alternative 2 Coolant mixed ready to use p 176 Mount the cap of the com...

Page 134: ... not meet specifications Rectify the coolant level and find out the cause of the loss Alternative 1 Coolant p 176 Alternative 2 Coolant mixed ready to use p 176 Mount the radiator cap 9 68 Checking the coolant level Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components ...

Page 135: ...reach of children 100283 10 Condition Engine is cold Stand the motorcycle on its side stand on a horizontal surface Check the coolant level in the compensating tank The coolant level must be within the range shown in the figure If the coolant level does not meet specifications Correct the coolant level Alternative 1 Coolant p 176 Alternative 2 Coolant mixed ready to use p 176 100284 10 Screw off t...

Page 136: ... poisonous and 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 and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolant out of the reach of children Remove the engine guard p 1...

Page 137: ...doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolant out of the reach of children 600618 10 Stand the motorcycle on its side stand on a horizontal surface Remove radiator cap 600619 10 Refill the coolant Alternative 1 Coolant p 176 Alternative 2 Coolant mixed ready ...

Page 138: ...rt the engine and run it until the 5th bar of the temperature indicator lights up Switch off the engine and allow it to cool down After the engine has cooled down check the coolant level in the radiator and in the compensating tank again and add more coolant if necessary 9 71 Adjusting basic position of clutch lever Info Turn the adjusting screw clockwise to increase the distance between the clutc...

Page 139: ...el of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc Do not use brake fluid Move the clutch fluid reservoir mounted on the handlebar to a horizontal position 100281 10 Remove screws Remove cover with membrane Check the fluid level Fluid level under top level of container 4 mm 0 16 in If the level of the coolant does not meet specifications Correct th...

Page 140: ...just the play in the throttle cable x p 139 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and let it run idle Move the handlebar to and f...

Page 141: ...motor drive to the basic position Loosen counter nut Set the play in the throttle cable by turning the adjusting screw Guideline Throttle cable play 3 5 mm 0 12 0 2 in Tighten counter nut 9 75 Removing the engine guard Stand the motorcycle on its side stand on a horizontal surface 100198 10 Remove screws on the left and right Pull the engine guard forward out of the holders and set it down ...

Page 142: ... engine oil level Info The engine oil level must be checked when the engine is warm Stand the motorcycle upright on a horizontal surface 100210 10 Condition The engine is at operating temperature 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 l...

Page 143: ... engine oil x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regula...

Page 144: ...lean 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 9 80 Removing the oil filter x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm ...

Page 145: ... regulations Place a suitable container under the engine 100202 10 Remove screws Remove the oil filter cover with the O ring Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000 100203 10 Remove screws Remove oil filter with the O ring Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean the pa...

Page 146: ...2 Cleaning the oil screens x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in ap...

Page 147: ...O rings 100206 10 Remove plug with oil screen and the O rings Completely drain the remaining engine oil 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 ...

Page 148: ... 11 1 lbf ft 9 83 Filling up with engine oil x Info Too little engine oil or poor quality engine oil results in premature wear to the engine 100209 10 Remove filler plug with O ring from the clutch cover and add engine oil Engine oil 1 70 l 1 8 qt Engine oil SAE 10W 60 00062010035 p 177 Alternative engine oil Engine oil SAE 10W 50 p 177 Refit plug with O ring and tighten it ...

Page 149: ...nd check that it is oil tight Install the engine guard p 140 Check the engine oil level p 140 9 84 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the engine 100209 10 Remove the oil filler plug with O ring from the clutch cover and fill up with engine oil Engine oil SAE 10W 60 00062010035 p 177 Engine oil SAE 10W 50 p 177 Info For optimal perfo...

Page 150: ...ing 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 without an effective exhaust extraction system Start the engine and check that it is oil tight Check the engine oil level p 140 ...

Page 151: ...t start Operating error Carry out the start procedure p 47 Fuse 4 blown Change the fuses of individual power consumers p 117 Coupling of fuel hose connection not connected Reconnect coupling of fuel hose connection Socket connector of wiring harness is oxidized Clean the socket connector and treat it with con tact spray Defect in fuel injection system Read out the fault memory using the KTM diag n...

Page 152: ...s flashes Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x Engine dies during the journey Lack of fuel Refuel p 54 Fuse 1 2 or 4 blown Change the fuses of individual power consumers p 117 High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary Engine oil level too high Check the engine oil level p 140 Engine ...

Page 153: ...s parked Recharge the battery x p 113 Battery is not charged by alternator Check the charging voltage x Check the quiescent current x Combination instrument shows nothing in the display Fuse 1 blown Change the fuses of individual power consumers p 117 Speedometer in combination instru ment not functioning Speedometer wiring harness is dam aged or plug in connection is oxidized Check the wiring har...

Page 154: ... FI warning lamp MIL flashes briefly 8x Error level condition Accelerator position sensor input signal too low Accelerator position sensor input signal too high Blink code FI of warning lamp MIL 09 FI warning lamp MIL flashes briefly 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 co...

Page 155: ...sure sensor input signal too low Ambient air pressure sensor input signal too high Blink code FI of warning lamp MIL 15 FI warning lamp MIL flashes 1x long 5x short Error level condition Rollover sensor 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 sensor cylinder 1 sensor 1 ...

Page 156: ...amp MIL 37 FI warning lamp MIL flashes 3x long 7x short Error level condition Ignition coil cylinder 1 circuit fault Blink code FI of warning lamp MIL 41 FI warning lamp MIL flashes 4x long 1x short Error level condition Fuel pump relay short circuit to ground or open circuit Blink code FI of warning lamp MIL 45 FI warning lamp MIL flashes 4x long 5x short Error level condition Lambda sensor heate...

Page 157: ...5x long 4x short Error level condition Secondary air valve short circuit to ground or open circuit Blink code FI of warning lamp MIL 58 FI warning lamp MIL flashes 5x long 8x 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 Blink code FI of warning lamp ...

Page 158: ... MIL 91 FI warning lamp MIL flashes 9x long 1x short Error level condition CAN bus communication error 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 159: ...licable regulations Info If you clean the motorcycle regularly its value and appearance will be maintained over a long period Avoid direct sunshine on the motorcycle during cleaning Seal the exhaust system to keep water out First remove coarse dirt particles with a gentle spray of water Spray very dirty areas with a normal motorcycle cleaner and then clean with a brush Motorcycle cleaner p 181 Inf...

Page 160: ...he motorcycle has cooled off oil or grease all moving parts and bearings Clean the chain p 75 Treat bare metal parts except for brake discs and exhaust system with anti corrosion materials Cleaning and preserving materials for metal rubber and plastic p 180 Treat all painted parts with a mild paint polish High luster polish for paint p 180 Treat all plastic parts and powder coated parts with a mil...

Page 161: ... clean it with cold water Warm water would enhance the corrosive effects of salt Clean the motorcycle p 157 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with a wax based anti corrosion substance Info To prevent serious reduction of the braking efficiency make sure no anti corrosion substance gets on to the brake discs After use on salted roads clean the m...

Page 162: ...ty as possible so that you can fill up with fresh fuel when you put the motorcycle back into operation Clean the motorcycle p 157 Change the engine oil and filter clean the oil screens x p 141 Check the antifreeze and coolant level p 130 Check the tire air pressure p 108 Remove the battery x p 111 Recharge the battery x p 113 Guideline Storage temperature of battery without direct sunshine 0 35 C ...

Page 163: ...ngine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 14 2 Putting into operation after storage Remove the motorcycle from the work stand p 60 Recharge the battery x p 113 Install the battery x p 112 Set the clock p 33 Refuel p 54 Carry out checks before putting into operation p 46 Make a test ride ...

Page 164: ...7 0 13 mm 0 0028 0 0051 in Crankshaft bearing 2 roller bearings Conrod bearing Needle bearing Piston pin bearing Bronze bush Pistons Forged light alloy Piston rings 1 L ring 1 tapered compression piston ring 1 oil scraper ring Engine lubrication Semi dry sump lubrication with two rotor pumps Primary transmission 36 79 Clutch APTC Antihopping clutch in oil bath hydraulically operated Gearbox 6 gear...

Page 165: ...AR 8AI 9 Spark plug electrode gap 0 9 mm 0 035 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid Electric starter automatic decompressor 15 1 Capacity engine oil Engine oil 1 70 l 1 8 qt Engine oil SAE 10W 60 00062010035 p 177 Alternative engine oil Engine oil SAE 10W 50 p 177 15 2 Capacity coolant Coolant 1 20 l 1 27 qt Coolant p 176 Coolant mixed ready to use p...

Page 166: ...il filter cover M5 6 Nm 4 4 lbf ft Screw oil pump cover M5 6 Nm 4 4 lbf ft Loctite 243 Plug vacuum connection M6 10 Nm 7 4 lbf ft Loctite 243 Screw in alternator cover M6 10 Nm 7 4 lbf ft Screw alternator cover chain shaft through hole M6 10 Nm 7 4 lbf ft Loctite 243 Screw autodecompression M6 3 4 Nm 2 2 3 lbf ft Loctite 243 Screw axial lock of camshaft M6 10 Nm 7 4 lbf ft Loctite 243 Screw clutch...

Page 167: ...e rail M6 10 Nm 7 4 lbf ft Loctite 243 Screw timing chain tensioning rail M6 10 Nm 7 4 lbf ft Loctite 243 Screw valve cover M6 10 Nm 7 4 lbf ft Screw water pump cover M6 10 Nm 7 4 lbf ft Screw water pump wheel M6 10 Nm 7 4 lbf ft Loctite 243 Oil jet piston cooling M6x0 75 4 Nm 3 lbf ft Loctite 243 Plug crankshaft location M8 20 Nm 14 8 lbf ft Stud exhaust flange M8 10 Nm 7 4 lbf ft Loctite 243 Cyl...

Page 168: ...gnet M12x1 5 20 Nm 14 8 lbf ft Oil pressure regulator valve plug M12x1 5 20 Nm 14 8 lbf ft Plug oil bore M14x1 5 15 Nm 11 1 lbf ft Loctite 243 Engine case stud M16x1 5 25 Nm 18 4 lbf ft Loctite 243 Rotor nut M18x1 5 100 Nm 73 8 lbf ft Nut engine sprocket M20x1 5 60 Nm 44 3 lbf ft Loctite 243 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 Lo...

Page 169: ...sc brake with dual piston brake caliper floating Rear Disc brake with single piston brake caliper floating Brake discs diameter Front 300 mm 11 81 in Rear 240 mm 9 45 in Brake discs wear limit Front 4 5 mm 0 177 in Rear 3 5 mm 0 138 in Tire air pressure road solo Front 1 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 Tire air...

Page 170: ...rmissible front axle load 150 kg 331 lb Maximum permissible rear axle load 200 kg 441 lb Maximum permissible overall weight 350 kg 772 lb Battery YTZ10S Battery voltage 12 V Nominal capacity 8 6 Ah maintenance free Fuse 58011109130 30 A Fuse 75011088015 15 A Fuse 75011088010 10 A 17 1 Lighting equipment Headlight S2 socket BA20d 12 V 30 35 W Parking light W5W socket W2 1x9 5d 12 V 5 W Instrument l...

Page 171: ... 90 21 M C 54R TT Pirelli MT 21 RALLYCROSS 140 80 18 M C 70R TT Pirelli MT 21 RALLYCROSS Additional information is available in the Service section under http www ktm com 17 3 Capacity fuel Total fuel tank capacity approx 12 l 3 2 US gal Super unleaded ROZ 95 RON 95 PON 91 p 179 Fuel reserve approx 2 5 l 2 6 qt ...

Page 172: ...ks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring length with preload spacer s 495 mm 19 49 in Spring rate Medium standard 5 2 N mm 29 7 lb in Air chamber length 100 0 20 mm 3 94 0 0 79 in Fork length 915 mm 36 02 in Fork oil per fork leg 635 ml 21 47 fl oz Fork oil SAE 5 p 178 ...

Page 173: ... 1 turn Compression damping low speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload 20 mm 0 79 in Spring rate Medium standard 80 N mm 457 lb in Spring length 220 mm 8 66 in Gas pressure 10 bar 145 psi Static sag 25 mm 0 98 in Riding sag 70 80 mm 2 76 3 15 in Fitt...

Page 174: ...TECHNICAL DATA SHOCK ABSORBER 172 Shock absorber oil p 178 SAE 2 5 ...

Page 175: ... seat lock M5 3 Nm 2 2 lbf ft Loctite 222 Screw side cover M5 2 Nm 1 5 lbf ft Screw side stand switch M5 3 Nm 2 2 lbf ft Screw starter cable on starter M5 3 Nm 2 2 lbf ft Spoke nipple rear wheel M5 4 Nm 3 lbf ft Nut foot brake cylinder screw M6 10 Nm 7 4 lbf ft Remaining nuts chassis M6 15 Nm 11 1 lbf ft Remaining screws on fuel tank M6 6 Nm 4 4 lbf ft Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 176: ...onnection lever on frame M8 30 Nm 22 1 lbf ft Screw exhaust clamp on main silencer M8 25 Nm 18 4 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw front footrest bracket M8 25 Nm 18 4 lbf ft Screw fuel tank bottom M8 20 Nm 14 8 lbf ft Screw handlebar clamp M8 20 Nm 14 8 lbf ft Loctite 243 Screw handrail M8 20 Nm 14 8 lbf ft Screw license p...

Page 177: ...Screw foot brake lever M10LH 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar support M10 40 Nm 29 5 lbf ft 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 Lambda sensor M12x1 25 24 5 Nm 18 07 lbf ft Copper paste Screw swingarm pivot M12x1 75 80 Nm 59 lbf ft Nut linkage lever on swingarm M14x1 5 100 Nm 73 8 lbf ft Nut linkage lever to rock...

Page 178: ...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 antifreeze can lead to corrosion and foaming KTM recommends Motorex products Mixture ratio Antifreeze protection 25 45 C 13 49 F 50 corrosion inhibitor antifreeze 50 distilled water Coolant mixed ready to us...

Page 179: ...he corresponding properties KTM recommends Motorex products Synthetic engine oil Supplier Motorex Motorex KTM Cross Power 4T Engine oil SAE 10W 50 According to JASO T903 MA p 183 SAE p 183 SAE 10W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties KTM recommends Motorex products Fully syntheti...

Page 180: ... fluid 15 According to ISO VG 15 Guideline Use only hydraulic fluid that complies with the specified standards see specifications on the container and that possesses the corre sponding properties KTM recommends Motorex products Supplier Motorex Hydraulic Fluid 75 Shock absorber oil SAE 2 5 50180342S1 According to SAE p 183 SAE 2 5 Guideline Use only oils that comply with the specified standards se...

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

Page 182: ...ing and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Supplier Motorex Protect Shine 645 Contact spray Guideline KTM recommends Motorex products Supplier Motorex Accu Contact High luster polish for paint Guideline KTM recommends Motorex products Supplier Motorex Moto Polish ...

Page 183: ...Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Off road chain spray Guideline KTM recommends Motorex products Supplier Motorex Chain Lube 622 Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean Polish ...

Page 184: ...AUXILIARY SUBSTANCES 182 Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Universal ...

Page 185: ...ce intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Stan dard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils ...

Page 186: ...anging 89 front brake checking 88 rear brake changing 97 rear brake checking 97 Brakes 52 Braking 52 C Chain checking 80 cleaning 75 dirt checking for 75 Chain guide adjusting 83 Chain tension adjusting 78 checking 77 Chassis number 22 Cleaning 157 158 Clutch checking correcting fluid level 137 Clutch lever 25 basic position adjusting 136 Combination instrument 29 clock setting 33 coolant temperat...

Page 187: ...Engine guard installing 140 removing 139 Engine number 23 Engine oil adding 147 changing 141 draining 141 refilling 146 Engine oil level checking 140 Engine sprocket checking 80 Environment 9 F Filler cap closing 37 opening 37 Flashing code 152 156 Foot brake lever 40 basic position adjusting 93 free travel checking 93 Fork 61 compression damping adjusting 61 dust boots cleaning 70 fork legs bleed...

Page 188: ...light mask with headlight installing 122 removing 120 Headlight setting checking 126 Horn button 27 I Ignition lock 28 Indicator lights 30 K Key number 23 L Light switch 26 Loading the vehicle 44 M Main fuse changing 115 Maintenance 7 Motorcycle cleaning 157 jacking up 60 removing from the work stand 60 O Oil filter changing 141 installing 144 removing 142 Oil screens cleaning 141 144 Owner s manu...

Page 189: ...ounting 111 removing 110 Seat release 38 Service schedule 57 59 Shift lever 39 Shifting 48 Shock absorber 61 compression damping general 63 compression damping high speed adjusting 64 compression damping low speed adjusting 63 rebound damping adjusting 65 riding sag checking 68 static sag checking 67 Shock absorber part number 24 Side stand 41 Spare parts 8 Spoke tension checking 109 Spring preloa...

Page 190: ...166 fork 170 shock absorber 171 172 Tire air pressure checking 108 Tire condition checking 107 Transport 8 Troubleshooting 149 151 Turn signal bulb changing 125 Turn signal switch 26 Type label 22 U Use definition 7 V View of vehicle front left 18 rear right side 20 W Warranty 7 Work rules 8 ...

Page 191: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 10 2009 Photo Mitterbauer 3211512en 3211512en ...

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