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KTM 690 SMC 2008, Repair Manual, Page: 200 / 227

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KTM 690 SMC 2008 Repair Manual Download Page 200

WIRING DIAGRAM

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690 Enduro/SMC 08/09/10

600981-01

Summary of Contents for 690 SMC 2008

Page 1: ...REPAIR MANUAL 2008 690 SMC EU 690 SMC AUS UK 690 SMC USA Article no 3206042en...

Page 2: ......

Page 3: ...modify or delete technical specifica tions prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well...

Page 4: ...e damper 35 Disassembling the piston rod 36 Checking the damper 37 Removing the heim joint 38 Installing the heim joint 39 Assembling the piston rod 40 Assembling the damper 41 Bleeding and filling th...

Page 5: ...Checking crankshaft run out at bearing pin 111 Installing balancer shaft drive wheel 111 Installing crankshaft bearing inner ring 111 Measuring axial clearance of crankshaft and balancer shaft 112 Cyl...

Page 6: ...nition coil checking the secondary winding 159 41 THROTTLE VALVE BODY 160 Checking the basic setting of the motor drive 160 Adjusting the basic setting of the motor drive 161 Flashing the EFI control...

Page 7: ...ge reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a testing step Identifies a voltage measurement Identifies a cur...

Page 8: ...s that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear Change damaged or worn parts Following repairs or servicing the vehicle must be checked for r...

Page 9: ...sis number is stamped on the right of the steering head The USA type label is on the right of the frame behind the steering head 700218 01 The Canada type label is on the right of the frame behind the...

Page 10: ...NUMBERS 8 3 5 Fork part number 600480 10 The fork part number is stamped on the inner side of the fork stub 3 6 Shock absorber part number 100216 10 The shock absorber part number is on the right of...

Page 11: ...le against falling over Remove the rear wheel stand and lean the vehicle on the side stand 4 3 Raising the motorcycle with the front wheel stand Note Danger of damage The parked vehicle may roll away...

Page 12: ...029036000 p 213 300201 10 Position the motorcycle upright align the special tool and raise the motorcycle Work stand 62529055000 p 211 4 6 Removing the motorcycle from the work stand Note Danger of da...

Page 13: ...ton Info Do not press the electric starter button until the function test of the combi nation instrument is finished When starting DO NOT open the throttle If you open the throttle during the starting...

Page 14: ...5 2 Adjusting rebound damping of fork Info The hydraulic rebound damping determines the fork suspension behavior 100244 10 Turn adjusting screws clockwise until they stop Info The adjusting screws are...

Page 15: ...n them with brake cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray p 207 Press the dust boots back into their normal position Remove excess...

Page 16: ...and Unscrew screw about 6 turns and press your hand on the screw to push the wheel spindle out of the axle clamp Remove screw Warning Danger of accidents Reduced braking efficiency caused by damaged...

Page 17: ...triple clamp The upper fork projection must be the same on both sides Tighten screws on both sides Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Screw bottom triple clamp M8 12 Nm 8 9 lbf ft 2...

Page 18: ...ews spacers but do not tighten Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a pressure point Fix the hand brake lever in the activated position Th...

Page 19: ...both fork legs Condition The fork legs have been removed 200660 01 Establish and note the current state of the rebound damping and compression damping Completely open the adjusters of the rebound and...

Page 20: ...on Open end wrench T14032 p 219 Info The preload spacers should be above the special tool 200647 12 Clamp the special tool in the vise Loosen screw cover 200648 12 Remove screw cover with preload spac...

Page 21: ...e and remove it with the sealing ring Info Place a container underneath to catch any oil that may run out 200653 01 Remove the cartridge 200654 12 Remove valve of the rebound damping with the spring f...

Page 22: ...ck apart by hand 200659 12 Take off the lower sliding bushing Take off support ring Take off seal ring Take off lock ring Take off dust boot 5 11 Checking the fork legs Condition The fork legs have be...

Page 23: ...with preload spacer s 480 mm 18 9 in If the measured value is greater than the specified value Reduce the strength of the pretensioning bushes If the measured value is less than the specified value I...

Page 24: ...Info Without using tools carefully pull the stack apart by hand 200672 10 Push on the outer tube Heat up the outer tube in area of the lower sliding bushings Guideline 50 C 122 F Hold the lower slidi...

Page 25: ...ainst the resistance of the spring Screw on fluid barrier as far as it will go Info The fluid barrier must be tightened as much as possible Do not use tools 200675 10 Install the special tool on the c...

Page 26: ...l part Open end wrench T14032 p 219 Remove the special tool Gripping tool T14026S1 p 218 200680 10 Clamp the special tool in the vise Grease the thread of the piston rod Lubricant T159 p 207 Grease th...

Page 27: ...Modifications to the suspension settings can seri ously alter the vehicle s ride behavior Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handli...

Page 28: ...heck the steering head bearing and change if necessary Remove the motorcycle from the work stand 5 14 Adjusting the steering head bearing play Raise the motorcycle and secure it against falling over T...

Page 29: ...M10 40 Nm 29 5 lbf ft Info Position the left and right handlebar supports evenly Position the handlebar Info Make sure cables and wiring are positioned correctly Position the handlebar clamp Fit and...

Page 30: ...hrottle cable 600631 10 Move the handlebar to the straight ahead position Use the KTM diagnostics tool to set the motor drive to the basic position Loosen counter nut Set the play in the throttle cabl...

Page 31: ...urn Info Turn clockwise to increase damping turn counterclockwise to reduce sus pension damping 7 2 Adjusting the low speed compression damping of the shock absorber Danger Danger of accidents Disasse...

Page 32: ...pension damping 7 4 Measuring the unloaded rear wheel sag Raise the motorcycle with the lift stand 0 0 A A 400988 10 Measure the vertical distance between the rear axle and a fixed point such as a ma...

Page 33: ...g p 32 7 7 Adjusting the spring preload 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 Adh...

Page 34: ...d 85 N mm 485 lb in Hard 90 N mm 514 lb in Info The spring rate is shown on the outside of the spring Install the shock absorber p 33 Check the static sag of the shock absorber p 30 Adjust the rebound...

Page 35: ...and remove 7 10 Installing the shock absorber 300566 11 Swing the rear end upwards and insert shock absorber from above 300565 11 Mount screw but do not tighten yet Mount and tighten screw Guideline S...

Page 36: ...bf ft Mount the side cover p 55 Remove the motorcycle from the work stand p 10 7 11 Servicing the shock absorber Danger Danger of accidents Disassembly of pressurized parts can lead to injury The shoc...

Page 37: ...ing ring and adjusting ring until the spring is fully relieved of ten sion 300581 10 Press down the spring with the special tool Spring compressor T101S p 217 Remove spring retainer 300582 10 Take off...

Page 38: ...in the oil 300587 10 Remove the piston rod Drain the remaining oil 300588 10 Remove compression damping adjuster Remove the spring sleeve and piston 300589 10 Push back membrane cover Remove lock ring...

Page 39: ...set the parts down together 300542 10 Remove seal ring retainer 300543 10 Remove locking cap and rubber buffer 7 15 Checking the damper Condition The damper has been disassembled 300596 10 Measure the...

Page 40: ...d Check the piston rod for damage and wear If there is damage or wear Change the piston rod 300460 01 Check the heim joint for damage and wear If there is damage or wear Change the heim joint 7 16 Rem...

Page 41: ...07S p 217 7 17 Installing the heim joint 200581 10 Place special tool underneath and press in the heim joint as far as the center using special tool Pressing tool T1206 p 217 Pressing tool T129 p 218...

Page 42: ...ricant T625 p 207 Remove the special tool 200572 11 Mount supporting plate with the rounded side facing downward Mount the compression shim stack with the smaller shims facing downward 300547 10 Sand...

Page 43: ...mping adjustment M26x1 30 Nm 22 1 lbf ft 300586 11 Mount and tighten screw Guideline Filling port screw M10x1 14 Nm 10 3 lbf ft 300592 10 Fill the damper cartridge about half full Shock absorber oil S...

Page 44: ...eed Comfort 1 5 turns Standard 1 turn Sport 0 5 turn Full payload 0 5 turn Turn adjusting screw clockwise up to the last perceptible click Turn back counterclockwise by the number of clicks correspond...

Page 45: ...filling the piston rod slides in and out do not prevent it from mov ing by holding it 200271 10 Place the control lever as shown in the photo The External tank control lever is on Closed Damper on Vac...

Page 46: ...bar The pressure gauge falls to the specified value 0 bar 200268 10 When the pressure gauge reaches the specified value turn the Damper control lever to Pressure Guideline 0 bar Oil is pumped into the...

Page 47: ...psi 300599 10 Open valve Fill the damper for at least 15 seconds Guideline Gas pressure 10 bar 145 psi Info Watch the pressure regulator dial Make sure that the damper is filled to the specified pres...

Page 48: ...7 Hook wrench T157S p 219 Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seri ously alter the vehicle s ride behavior Extreme modifications to the adjustment of...

Page 49: ...t touch hot components Remove the air filter box p 51 300210 10 Unplug connector of the lambda sensor Open the cable binder 300207 10 Remove screws Remove the heat shield 300208 10 Remove nuts of the...

Page 50: ...lbf ft Copper paste 300210 11 Plug in the connector of the lambda sensor Secure the cable with the cable binders 300207 11 Position the heat shield Mount and tighten screws Guideline Screw exhaust hea...

Page 51: ...2047 11 Position the main silencer Mount and tighten screws Guideline Screw main silencer holder M8 25 Nm 18 4 lbf ft 302045 10 Position the exhaust clamp Tighten screw Guideline Screw exhaust clamp o...

Page 52: ...05 EXHAUST 50 302046 11 Mount and tighten screws Guideline Rear fairing screw M5 2 Nm 1 5 lbf ft...

Page 53: ...e air filter box Mount air filter Info The air filter must lie flush against the air filter box along the entire sealing surface If the air filter is not correctly mounted dust and dirt can penetrate...

Page 54: ...spring loaded band type clamp 60029057100 p 210 Detach connector of the intake air temperature sensor Take off the air filter box 9 4 Installing the air filter box 300206 11 Attach connector of the i...

Page 55: ...Nm 7 4 lbf ft 300203 11 Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 300202 11 Position the voltage regulator Mount and tighten screws Guideline Remaining screws cha...

Page 56: ...g the seat 100230 10 Pull on strap and raise the rear of the seat at the same time Pull back the seat and lift it off 10 4 Mounting the seat 100276 10 Hook slot of the seat onto screw press the rear d...

Page 57: ...ts into your eyes rinse immedi ately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed con tact a doctor immediately Change clothing that ha...

Page 58: ...ighly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up sp...

Page 59: ...screw Repeat the operation on the opposite side Swing the rear end upwards and secure it 302607 10 Remove screws Pull out the fuel pump 302608 10 Remove hose clamps Remove fuel filter 302609 10 Press...

Page 60: ...pump M5 6 Nm 4 4 lbf ft 300564 10 Position the rear end Mount and tighten screw Guideline Screw fuel tank bottom M8 20 Nm 14 8 lbf ft Repeat the operation on the opposite side 300563 10 Lift the rear...

Page 61: ...such a way that the brake disc is not dam aged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork 600626 11 Remove distance bushings 11 2 Installing the front whee...

Page 62: ...ear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life 400695 01 Remove dust cap Check tire air pressure when tires are cold Tire air pr...

Page 63: ...the tires Check the age of the tires Info The tire s date of manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking The first two digits refer to...

Page 64: ...ning Danger of accidents No braking effect when operating the rear brake After installing the rear wheel always operate the foot brake until the pressure point is reached Check the rear hub rubber dam...

Page 65: ...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...

Page 66: ...justment range of the chain adjusters 30 mm 1 18 in enables different secondary transmissions with the same chain length The chain adjusters can be turned through 180 12 5 Adjusting chain guide 600635...

Page 67: ...ding guard is firmly seated If the chain sliding guard is loose Tighten the chain sliding guard Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 302112 10 Check the chain guide for wear If the c...

Page 68: ...procket facing upwards and insert the wheel spindle in the hub To check play hold the rear wheel tight and try to rotate the rear sprocket Info Measure the play on the outside of the rear sprocket Pla...

Page 69: ...s are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle 400998 01 Check the axial run out and radial run out of the rim Axial run out outs...

Page 70: ...ive plus cable of the battery Push the wiring harness to the side and pull the battery out of the battery rack Info Never operate the motorcycle with a discharged battery or without a battery In both...

Page 71: ...ur KTM dealer or to a recycling center that accepts used batteries Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should...

Page 72: ...Remove the seat p 54 302035 10 Remove screws Push the retaining bracket forward and take off the terminal cover Start the motorcycle to make checks p 11 601014 10 Measure the voltage between the spec...

Page 73: ...ndividual power consumers is located under the seat Switch off all power consumers and switch off the engine Remove the seat p 54 600604 11 Open fuse box cover 600606 10 Remove the defective fuse Guid...

Page 74: ...Select switch out of the holder 100238 10 Turn the adjusting wheel until the desired digit is next to marking Set the Map Select switch to Soft Set the adjusting wheel to position 1 Soft reduced homol...

Page 75: ...sician immediately Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Warning Danger of a...

Page 76: ...Adjust the basic setting of the hand brake lever to your hand size by turning adjust ing wheel Info Pull the brake lever forwards and turn the adjusting wheel Do not make any adjustments while riding...

Page 77: ...ntact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 100254 10 Move the brake fluid reservoir mounted on the handlebar to a horizont...

Page 78: ...evel 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 204 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid immediately with water 14 7 Checking th...

Page 79: ...e linings and therefore the brake power can differ considerably from the original KTM brake linings If brake linings are used that differ from the originals there is no guarantee that they comply with...

Page 80: ...e circuit The rear brake can fail due to overheating Adjust free travel on foot brake lever according to specifications 600599 10 Move the foot brake lever back and forth between the end stop and the...

Page 81: ...ts Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brake according to the service schedule 100258 10 Stand the vehicle upright Check the brake fluid level...

Page 82: ...les If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Environmental hazard Hazardous substances cause environmental damag...

Page 83: ...to the MAX mark Brake fluid DOT 4 DOT 5 1 p 204 Mount the screw cap with the washer and membrane Activate the foot brake lever until there is a firm pressure point Info Clean up overflowed or spilt b...

Page 84: ...690 SMC USA Press the MODE button repeatedly until the ODO mode is active Keep the MODE button and the SET button pressed simultaneously The time display begins to flash Press the MODE button to set...

Page 85: ...ustomer in writing that these modifications are performed at the customer s own risk and that the vehicle will no longer be approved for use on public roads once modified Condition The motorcycle is s...

Page 86: ...he boundary between light and dark does not meet specifications Adjust the headlight range p 84 15 7 Adjusting the headlight range Check the headlight setting p 84 800084 10 Turn adjusting screw to ad...

Page 87: ...p to the steering head 700543 01 Position groove on counterpiece 100296 10 Position brake hose guide Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 15 10 Changing the...

Page 88: ...sert a new headlight bulb into the headlight housing Headlight H4 socket P43t p 173 Fix the headlight bulb in the headlight using the spring bar Replace the rubber cap Attach the connector Install the...

Page 89: ...14 LIGHT SYSTEM INSTRUMENTS 87 Insert the screw and turn it counterclockwise first until it engages in the thread Tighten the screw slightly Check the flasher system function...

Page 90: ...ke off the shift lever 300214 10 Have an assistant operate the rear brake Bend up the lock washer Remove the nut of the engine sprocket with the lock washer Remove screws 300215 10 Remove nut Remove t...

Page 91: ...tions of the gear position sensor the crankshaft posi tion sensor and the alternator Remove the cable binders and release the cables 300188 10 Pull of the spark plug connector Unplug the connector of...

Page 92: ...e the swingarm pivot 300224 10 Lower the engine Info You should have an assistant for this step Make sure that the engine is sufficiently secured against falling over Protect the frame and attachments...

Page 93: ...ideline Engine carrying screw M10 45 Nm 33 2 lbf ft Loctite 243 Tighten the swingarm pivot Guideline Screw swingarm pivot M12x1 75 80 Nm 59 lbf ft Tighten the lower engine bracket Guideline Engine car...

Page 94: ...rod Position the clutch slave cylinder Mount and tighten screws Guideline Screw clutch slave cylin der M6x20 10 Nm 7 4 lbf ft Loctite 243 Screw clutch slave cylin der M6x35 10 Nm 7 4 lbf ft Mount the...

Page 95: ...adiator hoses Install the spring loaded band type clamps Install the exhaust manifold p 47 Disconnect the battery p 69 300802 10 Remove the oil filler plug with O ring from the clutch cover and fill u...

Page 96: ...ne on special tool Info Have an assistant help you or use a crane 17 2 Draining the engine oil 300002 10 Remove the oil drain plug with the magnet and seal ring Remove plug with oil screen and the O r...

Page 97: ...spacer of the countershaft 17 7 Removing gear position sensor 302126 10 Remove screws Remove the gear position sensor 300007 10 Remove O ring Remove contact pin and the contact springs 17 8 Removing...

Page 98: ...adiator hose Pull out the thermostat 17 10 Setting engine to ignition top dead center 300023 10 Turn the crankshaft counterclockwise until markings of the camshafts are flush with the marks of the cam...

Page 99: ...10 Remove the shaped washer 17 12 Removing clutch cover 300015 10 Remove screws Take off the clutch cover Take off the dowels Remove the clutch cover seal 17 13 Removing spacer and spring 300154 10 Re...

Page 100: ...mshaft out of the bearing seats Take the timing chain off the camshaft gear Remove the camshaft 17 17 Removing cylinder head 300029 10 Remove screws Alternately loosen screws and remove them Take off...

Page 101: ...he special tool to hold the rotor tight Holding spanner 75029091000 p 215 Loosen the nut of the rotor and remove it with the tab washer Info The crankshaft must not be blocked 302120 10 Install the sp...

Page 102: ...he timing chain Info Mark the direction of travel Take off the lock ring 300149 10 Pull of the timing chain sprocket with the special tool Extractor 59029033000 p 209 17 22 Removing crankshaft positio...

Page 103: ...up the lock washer 300054 10 Hold the clutch cage using the special tool and remove the nut of the inner clutch hub Gear segment 75029081000 p 215 Info Make sure that the crankshaft is not blocked Rem...

Page 104: ...10 Remove the lock ring of the starter idler gear and the torque limiter Take off the starter idler gear with the washers Remove the torque limiter with the washers and needle bearing 300065 10 Take o...

Page 105: ...d normal washers from both oil pumps Take off the oil pump toothed wheels 300071 10 Remove the pins and washers Remove screws Take off the oil pump cover 300072 10 Remove both oil pump shafts with int...

Page 106: ...e case The balancer shaft and the main shaft have a stop disk these usually stick to the bearing Take off the left section of the engine case Remove the special tool 300077 10 Remove dowels Remove O r...

Page 107: ...Ensure that the pins remain in place 300082 10 Remove the lock ring and the stop disk 300083 10 Pull both transmission shafts out of the bearing seats together Info The stop disk of the countershaft u...

Page 108: ...n the shaft seal rings of the water pump with the open side facing out so that it is flush Warm the engine case section again Guideline 150 C 302 F 300096 10 Insert the new cold bearings into the bear...

Page 109: ...spring with the piston valve out of the drill hole Remove any sealing mass remnants and clean the engine case section thoroughly Warm the engine case section in an oven Guideline 150 C 302 F Knock the...

Page 110: ...If the measured value does not equal the specified value Change the spring Check the piston valve for damage and wear If there is damage or wear Replace the piston valve 300093 10 Lubricate the pisto...

Page 111: ...alancer shaft drive wheel Remove the crankshaft bearing inner ring p 109 300133 10 Screw in 2 M6 screws in the threads Tighten the two screws evenly to pull the drive wheel off the crankshaft 18 6 Cha...

Page 112: ...the bearing Position the second crankweb 300139 10 Position the special tool with the heel at the bottom Pressing device for crankshaft complete 75029047000 p 213 Press the upper crankweb in as far a...

Page 113: ...100 C 212 F 300159 10 Place the drive wheel on the crankshaft The dowel of the crankshaft must fit in the drill hole The side of the drive wheel with the punch mark must be visible after assembly and...

Page 114: ...too large add compensation shims Install the crankshaft bearing inner ring p 111 300164 10 Mount the dial gauge support on the engine case and measure and note the axial clearance of the balancer sha...

Page 115: ...of the cylinder 400376 10 Check the sealing area of the cylinder head for distortion using a straight edge and the special tool Feeler gauge 59029041100 p 210 Cylinder cylinder head sealing area dist...

Page 116: ...irt at right angles to the piston pin at a dis tance Guideline Distance 31 5 mm 1 24 in Piston diameter Size I 101 955 101 965 mm 4 01397 4 01436 in Size II 101 965 101 975 mm 4 01436 4 01476 in Info...

Page 117: ...suction pump but it applies to all oil pumps 300106 10 Use a feeler gauge to measure the play between the external rotor and the engine case as well as between the external rotor and the internal rot...

Page 118: ...timing chain tensioner Info This requires considerable force since the oil has to be pressed out Release the timing chain tensioner Without pressure the timing chain tensioner expands fully 200172 10...

Page 119: ...timing chain securing guide for damage and wear If there is damage or wear Replace the timing chain securing guide Check timing chain for damage and wear If there is damage or wear Change the timing c...

Page 120: ...8 22 Removing valves 300115 10 Take the shims out of the valve spring retainers and lay them to one side accord ing to their normal built in position 300116 10 Pretension the valve springs using the s...

Page 121: ...s Valve spring Minimum length without valve spring cap 42 3 mm 1 665 in If the measured value does not equal the specified value Change the valve spring 18 25 Checking valve spring retainer 300162 10...

Page 122: ...ne the valve seat Blow compressed air through all oil holes and check that they are clear 18 27 Installing valves 0 0 1 1 0 0 0 0 2 2 0 0 3 3 0 0 5 5 0 0 4 4 300118 01 Position the valve spring cap In...

Page 123: ...rm shafts Guideline Screw rocker arm shaft M6 12 Nm 8 9 lbf ft 18 29 Dismantling antihopping clutch 300120 10 Clamp the clutch in a vise Info Use soft jaws Carefully loosen and gradually remove the sp...

Page 124: ...h rod Check the length of clutch springs Clutch spring length 31 5 33 5 mm 1 24 1 319 in If the clutch spring length is less than the specified value Change all clutch springs Check the contact surfac...

Page 125: ...ng clutch p 123 18 31 Preassembling antihopping clutch 300123 10 Lubricate the clutch discs thoroughly Push the support ring and the pretension ring on to the outer clutch hub Info The pretension ring...

Page 126: ...corrosion and stiffness in the shift forks If there is scoring or corrosion or if the shift fork is stiff Change the shift rail Check sliding plate in contact areas for wear If the sliding plate is wo...

Page 127: ...r fixed gear Remove the sixth gear idler gear Remove the split needle bearing and stop disk Remove lock ring Remove the third fourth gear sliding gear Remove lock ring Remove stop disk and the fifth g...

Page 128: ...3 3 500174 01 Check needle bearing for damage and wear If there is damage or wear Change the needle bearing Check the pivot points of main shaft and countershaft for damage and wear If there is damag...

Page 129: ...in every repair job Oil all parts carefully before assembling Check the transmission p 126 0 0 3 3 0 0 1 1 0 0 2 2 0 0 4 4 0 0 5 5 0 0 6 60 0 7 7 0 0 9 9 0 0 8 8 0 0 bk bk 0 0 bl bl 300127 01 Fix the...

Page 130: ...gear on the countershaft with the protruding collar facing downward Mount stop disk and lock ring Mount the sixth gear sliding gear with the shift groove facing upward Install lock ring and stop disk...

Page 131: ...is damage or wear Replace the freewheel gear and or the bearing Check the freewheel when removed for damage and wear If there is damage or wear Replace the freewheel Check the toothing of the starter...

Page 132: ...of the freewheel gear If the primary gear does not turn clockwise or if it does not lock counterclock wise Remove the freewheel p 129 Turn the freewheel 180 Install the freewheel p 130 18 42 Installin...

Page 133: ...30 ENGINE WORK ON INDIVIDUAL PARTS 131 300127 11 Insert the lock ring into the groove with suitable pliers and check that it is seated correctly...

Page 134: ...haft 300088 10 Lubricate all bearings Assemble the two transmission shafts and slide them into the bearing seats together 300089 10 Mount the upper shift fork the middle shift fork and the lower shift...

Page 135: ...haft into the bearing seat and take off the special tool Align marks and Mount stop disk 19 3 Installing left engine case 300077 11 Mount the dowels Mount the O ring Degrease the sealing area Apply th...

Page 136: ...pump covers Mount and tighten the screws Guideline Screw oil pump cover M5 6 Nm 4 4 lbf ft Loctite 243 Install washers and pins 300070 11 Mount the oil pump gears washers and lock washers 19 5 Install...

Page 137: ...he way Let the sliding plate engage in the shift drum locating Shift through the transmission 19 8 Installing starter drive 300065 11 Install the two needle bearings and the woodruff key Push on the f...

Page 138: ...age in the clutch cage Info If necessary turn the main shaft a little to ease access Make sure that the upper clutch disc is offset by one notch 302121 10 Position a new lock washer and install the nu...

Page 139: ...on sensor Mount screws but do not tighten them yet Guideline Screw ignition pulse gen erator M6 10 Nm 7 4 lbf ft Loctite 243 Position the cable and push the cable support sleeve into the engine case 1...

Page 140: ...the collar of the screw otherwise the timing chain tension rail could lock and break Check both timing chain rails for freedom of motion 19 14 Installing rotor 300042 10 Ensure that the spring washer...

Page 141: ...piston into the special tool Piston assembly ring 75029015102 p 212 300033 10 Position the piston on the cylinder using the special tool Push the piston carefully into the cylinder from above The pis...

Page 142: ...Turn the special tool counterclockwise thereby pressing the piston pin retainer into the groove Piston pin lock ring insert 75029035000 p 213 Make sure that the piston pin retainer is seated correctl...

Page 143: ...19 19 Installing camshafts 300163 10 Lay the timing chain over the camshaft Push the timing chain into the bearing seats The middle drill hole of the camshaft and the drill hole of the cylinder head...

Page 144: ...ool Crank the engine several times Set the engine to ignition top dead center p 96 300155 10 Check the valve clearance on all valves between the valve and the rocker arm using the special tool Guideli...

Page 145: ...rds 300156 11 Install and tighten the screws of the rocker arm shafts Guideline Screw rocker arm shaft M6 12 Nm 8 9 lbf ft Check the valve clearance p 142 19 23 Installing spark plug 300016 11 Mount a...

Page 146: ...eline Screw water pump wheel M6 10 Nm 7 4 lbf ft Loctite 243 19 27 Installing thermostat 300010 11 Position the thermostat with the gasket The drill hole must face upward Install the thermostat case w...

Page 147: ...ensor Position O ring 302126 11 Install the gear position sensor Position the ground wire Mount and tighten the screws Guideline Screw gear sensor M5 5 Nm 3 7 lbf ft Loctite 243 19 30 Installing the s...

Page 148: ...l and tighten the plug with O rings Guideline Plug oil screen M20x1 5 15 Nm 11 1 lbf ft 300161 11 Position the oil screen with O rings Install and tighten the plug with O rings Guideline Plug oil scre...

Page 149: ...motor Long life grease p 206 Mount and tighten screws Guideline Screw starter motor M6 10 Nm 7 4 lbf ft Loctite 243 19 34 Installing valve cover 300003 10 Put the valve cover in place with the seal Mo...

Page 150: ...h 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 th...

Page 151: ...g drain hole of water pump M10x1 15 Nm 11 1 lbf ft 21 2 Filling the cooling system Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and...

Page 152: ...or immedi ately Change clothes that have come into contact with coolants Keep coolant out of the reach of children Condition Engine is cold 100283 10 Stand the motorcycle on its side stand on a horizo...

Page 153: ...coolant is swallowed contact a doctor immedi ately Change clothes that have come into contact with coolants Keep coolant out of the reach of children Condition Engine is cold 100283 10 Stand the moto...

Page 154: ...6 Rocker arm shaft 7 Transmission 8 Clutch 9 Oil jet for piston cooling 10 Oil filter 11 Crankshaft 12 Oil screen 13 Suction pump 7 Transmission 22 2 Checking the engine oil level Info The engine oil...

Page 155: ...e regulations 302039 10 Remove screw 302040 10 Position the banjo bolt with the connector and sealing rings Mount and tighten the banjo bolt Guideline Banjo bolt M10x1 8 Nm 5 9 lbf ft Oil pressure ada...

Page 156: ...2 10 Drain the engine oil p 154 Remove the oil filter p 155 Clean the oil screens p 156 Install the oil filter p 155 Fill up with engine oil p 157 22 5 Draining engine oil Warning Danger of scalding E...

Page 157: ...e environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Place a suitable container under the engine 100202 10 Remove screw...

Page 158: ...be disposed of as stipulated in applicable regulations Place a suitable container under the engine 100205 10 Remove screw plug with oil screen and the O rings 100206 10 Remove screw plug with oil scre...

Page 159: ...nd check that it is oil tight Check the engine oil level p 152 22 10 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the engine 100209 10 Remove th...

Page 160: ...1 Stator connector EN pin 3 Alternator Resistance of stator winding at 20 C 68 F 1 If the displayed value is not equal to the setpoint value Replace the stator 600894 10 601014 10 Stator winding check...

Page 161: ...as been removed Remove the fuel tank 600739 13 Ignition coil cylinder 1 check the secondary winding resistance Measure the resistance between the specified points Ignition coil pin 2 Ignition coil pin...

Page 162: ...or drive moves the throttle valve to the basic position completely closed 400790 60 Determine the voltage value via the Test button Info The Continue button only appears if the measured value equals t...

Page 163: ...161 Close the menu with Continue 24 2 Adjusting the basic setting of the motor drive Condition The diagnostics tool is connected Remove the air filter box p 51 601136 10 Disconnect the connector of t...

Page 164: ...r finger and hold it Check the voltage value Info The Continue button only appears if the measured value equals the set point value Throttle position sensor circuit A Basic position voltage THAD 0 50...

Page 165: ...nue to start the Adjusting the position of the throttle grip sensor menu Check the voltage value Info The Continue button only appears if the measured value equals the set point value Throttle grip se...

Page 166: ...oisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space...

Page 167: ...I control unit and or the EPT control unit is connected The ignition is on The diagnostics tool is connected and running Flashing of the EFI control unit and or the EPT control unit is completed 40068...

Page 168: ...For new control units a sample VIN is displayed For used control units the last programmed VIN is displayed Press Continue Select Code entry Please enter the code Press Continue The new VIN is written...

Page 169: ...41 THROTTLE VALVE BODY 167 Switch to the main menu Select Show identification Compare the old VIN to the new VIN The new VIN is shown...

Page 170: ...lutch APTC Antihopping clutch in oil bath hydraulically operated Gearbox 6 gears claw shifted Transmission ratio 1st gear 14 35 2nd gear 16 28 3rd gear 21 28 4th gear 21 23 5th gear 23 22 6th gear 23...

Page 171: ...in Piston ring groove clearance 0 08 mm 0 0031 in Piston ring end gap Compression rings 0 80 mm 0 0315 in Oil scraper ring 1 00 mm 0 0394 in Piston piston pin hole diameter 20 010 20 020 mm 0 78779 0...

Page 172: ...70 Main shaft axial clearance 0 10 0 40 mm 0 0039 0 0157 in Transmission shaft run out 0 025 mm 0 00098 in Shift shaft play in sliding plate shift quadrant 0 40 0 80 mm 0 0157 0 0315 in Fuel pressure...

Page 173: ...bf ft Screw cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw cylinder head M6 10 Nm 7 4 lbf ft Loctite 243 Screw engine case M6 10 Nm 7 4 lbf ft Screw ignition pulse generator M6 10 Nm 7 4 lbf ft Loctit...

Page 174: ...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 sprocke...

Page 175: ...t 2 0 bar 29 psi Rear 2 2 bar 32 psi Secondary drive ratio 16 42 Chain 5 8 x 1 4 X ring Steering head angle 63 Wheelbase 1 480 15 mm 58 27 0 59 in Seat height unloaded 900 mm 35 43 in Ground clearance...

Page 176: ...58W TL Pirelli Dragon Supercorsa Pro 160 60 ZR 17 M C 69W TL Pirelli Dragon Supercorsa Pro Additional information is available in the Service section under http www ktm com 28 2 Capacity fuel Total fu...

Page 177: ...10 clicks Rebound damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks Full payload 5 clicks Spring length with preload spacer s 480 mm 18 9 in Spring rate Soft 5 0 N mm 28 6 lb in Medium stand...

Page 178: ...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 18 mm 0 71 in Spring rate Soft 80...

Page 179: ...Nm 7 4 lbf ft Loctite 243 Screw brake fluid reservoir of rear brake M6 5 Nm 3 7 lbf ft Screw front brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw ignition lock M6 10 Nm 7 4 lbf ft Loctite 243 Screw...

Page 180: ...m 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 Screw front brake...

Page 181: ...nhances the corrosive effects of salt After the motorcycle has been thoroughly cleaned with a gentle spray of water it should be dried with compressed air and a cloth Warning Danger of accidents Reduc...

Page 182: ...it with cold water Warm water would enhance the corrosive effects of salt Clean the motorcycle p 179 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with a wax...

Page 183: ...torage temperature of battery without direct sunshine 0 35 C 32 95 F The storage place should be dry and not subject to large temperature differences Info KTM recommends jacking up the motorcycle Rais...

Page 184: ...brake fluid level p 74 Bleed the fork legs p 12 Check the steering head bearing play p 25 Change the spark plug Check the valve clearance Check all hoses e g fuel cooling bleeder drainage etc and bel...

Page 185: ...183...

Page 186: ...1 2 3 2 2 C1 1 G20 2 3 EN 3 1 K11 2 1 4 3 1 AF 4 X13 2 1 a AF 4 X13 3 EB 4 X19 3 4 c 1 0 3 X 2 0 3 X 1 2 A7 A11 43 2 DS 44 X18 43 AU 2 X12 2 EB 4 X19 4 b 10A F9 1 2 FJ 2 X9 1 CR 1 X292 1 CR 1 X291 1 F...

Page 187: ...Battery G20 Generator K10 Starter relay with main fuse K11 Start auxiliary relay M10 Starter motor T20 Voltage regulator X291 Connector for accessory ground terminal 31 ACC 1 not assigned X292 Connect...

Page 188: ...DS 44 X18 8 2 d EB 4 X15 3 e S23 BK 4 BK 4 4 3 1 2 EB 4 X14 4 BY 4 X41 3 BY 4 X41 4 3 A3 P10 BR 4 X37 4 2 2 BR 4 X37 3 7 A6 A12 1 DT 36 X21 1 1 DS 44 X18 1 b 1 FJ 2 X1 2 S11 CV 4 CV 4 4 3 2 1 1 ED 32...

Page 189: ...187 A11 EFI control unit A12 EPT control unit F1 Fuse K12 Light relay K30 Power relay P10 Combination instrument S11 Ignition steering lock S23 Emergency OFF switch electric starter button X295 Diagno...

Page 190: ...B1 f g c d DI 2 X61 1 DI 2 X61 2 3 6 4 2 5 1 5 C1 S29 BC 12 BC 12 E13 1 2 3 2 1 BP 4 X29 2 3 BP 4 X29 4 1 DG 4 X28 2 3 DG 4 X28 4 BW 3 X23 3 3 6 BW 3 X23 2 AC 6 X34 4 2 A3 P10 5 A1 AC 6 X34 5 15A F7...

Page 191: ...WIRING DIAGRAM 189 E13 Low beam high beam F6 Fuse F7 Fuse P10 Combination instrument P15 Horn P35 Parking light S29 High beam low beam switch horn button turn signal switch...

Page 192: ...4 10 f c 3 F8 f c B76 AK 2 AK 2 2 1 AH 2 X26 1 AH 2 X27 1 B77 AK 2 AK 2 2 1 AJ 3 X32 3 E60 1 2 1 AH 2 X27 2 AH 2 X26 2 DI 2 X58 2 DI 2 X58 1 P36 BG 3 BG 3 BS 2 BS 2 1 2 3 1 2 BV 2 X22 1 BV 2 X22 2 AJ...

Page 193: ...WIRING DIAGRAM 191 B76 Front brake light switch B77 Brake light switch rear E60 License plate lamp P36 Brake tail light...

Page 194: ...CX 2 X46 2 3 CV 4 X59 4 3 BY 4 X60 4 CX 2 X47 1 CX 2 X46 1 3 C3 S29 BG 3 BG 3 2 3 1 CV 4 X59 2 BY 4 X60 2 AH 2 X20 1 3 A3 P10 7 A1 BT 3 X17 1 2 BT 3 3 AH 2 X20 2 CX 2 X30 1 P42 1 CW 2 2 CW 2 CX 2 X30...

Page 195: ...K20 Turn signal relay P10 Combination instrument P41 Turn signal front left P42 Turn signal front right P45 Turn signal rear left P46 Turn signal rear right S29 High beam low beam switch horn button...

Page 196: ...5 4 3 2 1 M t 5 F8 3 B8 7 F1 6 10 M14 BI 2 BI 2 1 2 B33 2 1 10A F5 1 2 FJ 2 X5 1 10A F8 1 2 FJ 2 X8 1 AU 2 X10 2 c d AV 2 X33 1 AV 2 X33 2 c CR 1 X294 1 CR 1 X293 1 AU 2 X10 1 FJ 2 X8 2 FJ 2 X5 2 gn...

Page 197: ...AM 195 B33 Temperature switch for radiator fan F5 Fuse F8 Fuse M14 Radiator fan X293 Connector for accessory ground terminal 31 ACC 2 not assigned X294 Connector for accessory plus terminal 15 ACC 2 n...

Page 198: ...60 FK 8 7 8 6 5 4 3 2 1 30 29 24 31 14 16 15 13 30 1 29 2 24 3 31 4 14 5 16 6 15 7 DT 36 X21 13 DR 8 X39 8 2 A1 A12 DT 36 X21 36 35 10 AP 6 X295 4 10A F3 1 2 FJ 2 X3 1 5 A1 P10 8 A7 FJ 2 X2 2 FJ 2 X4...

Page 199: ...WIRING DIAGRAM 197 A11 EFI control unit A12 EPT control unit F2 Fuse F3 Fuse F4 Fuse M13 Fuel pump M60 Motor drive P10 Combination instrument X295 Diagnostics connector...

Page 200: ...F 2 X40 2 18 DS 44 X18 18 41 DS 44 X18 41 22 DS 44 X1822 FM 1 X48 1 12 DS 44 X18 12 FS 4 X45 2 42 42 4 25 25 i FS 4 X45 1 M20 1 2 7 A1 P10 9 A7 DW 2 X42 1 DQ 2 X43 1 2 ED 32 X63 2 B70 CZ 3 CZ 3 1 2 3...

Page 201: ...EFI control unit B51 Lambda sensor cylinder 1 B70 Front wheel speed sensor M20 Fuel evaporation valve USA version only M21 Secondary air valve M51 Injector cylinder 1 P10 Combination instrument R51 Ig...

Page 202: ...3 X49 3 DS 44 X18 26 32 31 10 32 1 31 2 DS 44 X18 10 AM 3 X50 3 15 DS 44 X18 15 AP 6 X51 5 34 DS 44 X18 34 i i AR 3 X49 2 4 4 DS 44 X18 4 j 1 AP 6 X51 6 11 13 DS 44 X18 13 AM 3 X36 1 DS 44 X18 11 AR...

Page 203: ...A11 EFI control unit B10 Throttle position sensor circuit A B12 Intake air temperature sensor B26 Rollover sensor B30 Side stand switch B31 Accelerator position sensor B34 Gear position sensor P10 Com...

Page 204: ...2 2 14 DP 3 X53 3 DS 44 X18 14 35 DS 44 X18 35 c AL 2 X54 1 44 20 DS 44 X18 20 44 DV 2 X55 2 33 DS 44 X18 33 DV 2 X55 1 2 DS 44 X18 2 AL 2 X54 2 36 36 1 EC 3 X57 3 38 38 i DP 3 X53 2 EC 3 X57 2 1 j AT...

Page 205: ...sensor cylinder 1 B32 Fuel level indicator B37 Crankshaft position sensor B38 Clutch switch B41 Manifold absolute pressure sensor cylinder 1 P10 Combination instrument S55 Map Select Switch bl Black...

Page 206: ...hibitor antifreeze 50 distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Supplier Motorex Anti Freeze Engine oil SAE 10W 60 00062010035 According to JASO T903 MA p 220 SAE p 220 SAE 10W 6...

Page 207: ...ine Use only hydraulic oil that complies with the specified standard see specifications on the container and that possesses the corre sponding properties KTM recommends Motorex products Supplier Motor...

Page 208: ...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...

Page 209: ...ine KTM recommends Molykote products Supplier Molykote 33 Medium Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Paint cleaner and polish for high gloss an...

Page 210: ...01 Art no 15112017000 Insert for bearing puller 400125 01 Art no 15112018100 Feature 18 23 mm 0 71 0 91 in Bleed syringe 400058 01 Art no 50329050000 Circlip pliers reverse 400059 01 Art no 5101201100...

Page 211: ...ner bearing race 400082 01 Art no 58429037043 Mounting sleeve 400095 01 Art no 58529005000 Valve spring compressor 400101 01 Art no 59029019000 Limit plug gauge 400104 01 Art no 59029026006 Extractor...

Page 212: ...10 12 5 3 5 400110 01 Art no 59029041100 Hose clamp pliers 400142 01 Art no 60029057000 Pliers for spring loaded band type clamp 400085 01 Art no 60029057100 Rear wheel stand 500077 01 Art no 6102905...

Page 213: ...t wheel stand 500078 01 Art no 61029055300 Testing hose 201314 01 Art no 61029093000 Pressure testing tool 400149 01 Art no 61029094000 Engine work stand 200306 01 Art no 61229001000 Work stand 400151...

Page 214: ...ne work stand 400153 01 Art no 75012001060 Holder for engine work stand 400154 01 Art no 75012001070 Piston assembly ring 400156 01 Art no 75029015102 Extractor 400157 01 Art no 75029021000 Assembly s...

Page 215: ...insert 400160 01 Art no 75029035000 Work stand adapter 400161 01 Art no 75029036000 Push in drift 500163 01 Art no 75029044010 Push in drift 500162 01 Art no 75029044020 Pressing device for crankshaft...

Page 216: ...ressing out tool 400186 01 Art no 75029047050 Under part pressing out tool 400187 01 Art no 75029047051 Extractor 400162 01 Art no 75029048000 Clamping plate 400163 01 Art no 75029050000 Push out drif...

Page 217: ...jack attachment 400184 01 Art no 75029055000 Mounting sleeve 400165 01 Art no 75029080000 Gear segment 400068 01 Art no 75029081000 Protection cover 400167 01 Art no 75029090000 Holding spanner 40016...

Page 218: ...rt no 75029172000 Oil pressure adapter 400176 01 Art no 77329006000 Engine blocking screw 400177 01 Art no 77329010000 Release device for timing chain tensioner 400181 01 Art no 77329051000 Valve spri...

Page 219: ...SPECIAL TOOLS 217 Spring compressor 300573 10 Art no T101S Hook wrench 301085 01 Art no T106S Pin 201235 10 Art no T120 Pressing tool 200583 10 Art no T1206 Pressing tool 200585 01 Art no T1207S...

Page 220: ...IAL TOOLS 218 Vacuum pump 200273 10 Art no T1240S Pressing tool 200584 01 Art no T129 Protecting sleeve 200635 10 Art no T1401 Gripping tool 200639 10 Art no T14026S1 Assembly tool 200634 10 Art no T1...

Page 221: ...AL TOOLS 219 Open end wrench 200640 10 Art no T14032 Clamping stand 200637 10 Art no T1403S Mounting sleeve 300569 10 Art no T1515 Filling adapter 300567 10 Art no T1516 Hook wrench 200899 10 Art no T...

Page 222: ...ce intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated wi...

Page 223: ...over installing 147 water pump cover mounting 144 B Battery connecting 69 disconnecting 68 fitting 68 recharging 69 removing 68 Brake discs checking 61 Brake fluid front brake adding 75 front brake ch...

Page 224: ...rter drive checking 129 freewheel checking 130 freewheel installing 130 freewheel removing 129 left engine case section 107 main shaft assembling 127 main shaft disassembling 125 oil pumps for wear ch...

Page 225: ...hanging 85 Play in throttle cable adjusting 28 checking 27 Protective treatment for winter operation 180 Putting into operation after storage 181 R Rear hub rubber dampers checking 66 Rear sprocket ch...

Page 226: ...ear limits 169 170 engine tightening torques 171 172 fork 175 shock absorber 176 Tire air pressure checking 60 Tire condition checking 60 Type label 7 W Warranty 6 Wiring diagram 184 203 page 1 of 10...

Page 227: ...3206042en 3206042en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 02 2010 Photo Mitterbauer...

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