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KTM 690 SMC R 2014, Owner'S Manual, Page: 78 / 195

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KTM 690 SMC R 2014 Owner'S Manual Download Page 78

11

SERVICE WORK ON THE CHASSIS

76

11.12

Removing the air filter

x

Preparatory work

–

Remove the seat. (

p. 75)

601882-10

Main work

–

Remove screws

. Take off air filter box top

.

601880-10

Note

Engine failure

 

Unfiltered intake air has a negative effect on the service life of the

engine.

–

Never operate the vehicle without an air filter as dust and dirt will enter the engine
and lead to increased wear.

–

Remove air filter

.

Summary of Contents for 690 SMC R 2014

Page 1: ...OWNER S MANUAL 2014 690 SMC R EU 690 SMC R AUS UK Art no 3213104en...

Page 2: ......

Page 3: ...All specifications are non binding KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications prices colors forms materials services designs equipment etc wit...

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

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

Page 6: ...g the high speed compression damping of the shock absorber 65 10 7 Adjusting the rebound damping of the shock absorber 66 10 8 Handlebar position 67 10 9 Adjusting the handlebar position x 68 11 SERVI...

Page 7: ...ressure 110 13 9 Checking the spoke tension 111 14 ELECTRICAL SYSTEM 113 14 1 Removing the battery x 113 14 2 Installing the battery x 114 14 3 Recharging the battery x 115 14 4 Changing the main fuse...

Page 8: ...ance steps for winter operation 153 19 STORAGE 155 19 1 Storage 155 19 2 Preparing for use after storage 157 20 TROUBLESHOOTING 158 21 BLINK CODE 161 22 TECHNICAL DATA 167 22 1 Engine 167 22 2 Engine...

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

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

Page 11: ...n Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken 2 4 Tampering warning Tampering with the noise control system is prohibited Federal law p...

Page 12: ...may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust...

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

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

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

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

Page 17: ...15...

Page 18: ...4 VIEW OF VEHICLE 16 4 1 View of vehicle front left side example 101971 10...

Page 19: ...nd brake lever p 23 2 Clutch lever p 23 3 Handrails p 38 4 Filler cap 5 Engine number p 21 6 Shift lever p 39 7 Side stand p 41 8 Seat release p 38 9 Compression damping of the shock absorber p 64 10...

Page 20: ...4 VIEW OF VEHICLE 18 4 2 View of vehicle rear right side example 101972 10...

Page 21: ...switch p 25 3 Horn button p 24 4 Function buttons p 28 4 Indicator lamps p 29 5 Emergency OFF switch p 26 5 Electric starter button p 26 6 Throttle grip p 24 7 Fork rebound adjustment 8 Chassis numbe...

Page 22: ...5 SERIAL NUMBERS 20 5 1 Chassis number 401945 10 The chassis number is stamped on the steering head on the right 5 2 Type label 101973 10 The type label is located on the right side of the frame...

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

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

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

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

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

Page 28: ...ted a running engine stops and the engine cannot be started Emergency OFF switch on This position is necessary for operation as the ignition circuit is closed 6 8 Electric starter button B01947 11 The...

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

Page 30: ...raveled ODO trip master 1 TRIP 1 and trip mas ter 2 TRIP 2 Press the SET button to reset the trip master 1 function TRIP 1 and trip master 2 func tion TRIP 2 to 0 0 Button has no function 6 10 3 Tacho...

Page 31: ...switched on The temperature warning lamp lights up red The coolant temperature has reached a critical value The low fuel warning lamp lights up yellow The fuel level has reached the reserve mark The...

Page 32: ...t up for a second as a function test 400881 01 LEnGth Following the display function test the LEnGth wheel circumference is shown for one sec ond Info 1870 mm corresponds to the circumference of the 1...

Page 33: ...shown in kilometers per hour km h or in miles per hour mph 6 10 7 Setting kilometers or miles Info If you change the unit the value ODO is retained and converted accordingly Making the setting accord...

Page 34: ...the ODO mode is active Keep the MODE button pressed until the display mode changes from km h to mph or from mph to km h 6 10 8 Time 401443 11 The time is shown in area of the display Info After recon...

Page 35: ...and the SET button pressed simultaneously The time is set 6 10 10 ODO display 401444 01 In the ODO display mode the total distance traveled is shown in kilometers or miles Info This value is retained...

Page 36: ...IP 2 Info The TRIP 2 trip counter is always running 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...

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

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

Page 39: ...ound or the sewage system 101975 10 Lift the cover of filler cap and insert the ignition key Turn the ignition key 90 counterclockwise and remove the filler cap Info The filler cap has a fuel tank bre...

Page 40: ...t release 101977 10 The seat can be released using strap 6 14 Handrails 101978 10 The handrails are used for moving the motorcycle around When you have a passenger the passenger can hold on the handra...

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

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

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

Page 44: ...crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control...

Page 45: ...service record at vehicle handover Before your first trip read the entire operating instructions carefully Get to know the controls Adjust the basic position of clutch lever p 86 Adjust the basic posi...

Page 46: ...lmet baggage Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and or tank rucksack Mount and secure suitcase and tank rucksack according to the manuf...

Page 47: ...ble handling characteristics due to slipped baggage Check the way your baggage is fixed regularly Warning Danger of burns A hot exhaust system can burn baggage Fasten your baggage in such a way that i...

Page 48: ...ke fluid level p 96 Check the front brake linings p 93 Check the rear brake linings p 98 Check the brake system function Check the coolant level p 134 Check the chain for dirt p 78 Check the chain ten...

Page 49: ...ver operate the vehicle with a discharged battery or without a battery Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always warm up th...

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

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

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

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

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

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

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

Page 57: ...ignition lock power continues to flow to most power consumers and the battery will discharge You should therefore always switch off the engine with the ignition key the emergency OFF switch is intende...

Page 58: ...he vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel...

Page 59: ...ly refuel with clean fuel that meets the specified standards Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the gr...

Page 60: ...SET button for two seconds The fuel level warning lamp switches off TRIP F is set to 0 0 and the display returns to the previous display mode Info If you do not press the SET button the reset takes pl...

Page 61: ...eck the front brake linings p 93 Check the rear brake linings p 98 Check the brake discs p 90 Check the brake lines for damage and leakage Check the rear brake fluid level p 96 Check the free travel o...

Page 62: ...alve clearance x Check all hoses e g fuel cooling bleeder drainage etc and sleeves for cracking leaks and incorrect routing x Check the antifreeze and coolant level p 132 Check the cables for damage a...

Page 63: ...621 4 mi Check the headlight setting p 130 Check that the radiator fan is functioning properly x Final check Check the vehicle for roadworthiness and take a test ride Read out the fault memory using...

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

Page 65: ...fork Info The hydraulic rebound damping determines the fork rebound behavior 101982 10 Turn the red adjusting screw all the way clockwise Info Adjusting screw is located at the upper end of the right...

Page 66: ...the landing after a jump the rear wheel suspension compresses more quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses more...

Page 67: ...shock absorber type Guideline Compression damping low speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full load capacity 15 clicks Info Turn clockwise to increase damping turn counterclock...

Page 68: ...shock absorber type Guideline Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduc...

Page 69: ...icks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 10 8 Handlebar position 601874 10 In the upper triple clamp there are 2 drill holes separated by a distance of Hole...

Page 70: ...move the two screws Take off the handlebar holder Move the handlebar holder to the desired position Mount and tighten the two screws Guideline Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243...

Page 71: ...e vehicle on a firm and even surface 401942 01 Stand the motorcycle upright on a level surface Raise the motorcycle in the area of the footrest bracket Secure the motorcycle against falling over 11 2...

Page 72: ...with the rear wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 101984 10 Insert the adapter into the rear wheel stan...

Page 73: ...firm and even surface 401943 10 Secure the motorcycle against falling over Remove the rear wheel stand and lean the vehicle on the side stand 11 5 Raising the motorcycle with the front wheel stand No...

Page 74: ...otorcycle first Raise the front of the motorcycle 11 6 Taking the motorcycle off of the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle o...

Page 75: ...e dust boots 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 clean them with bra...

Page 76: ...the fork protector 11 9 Installing the fork protector 101986 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 Posit...

Page 77: ...back the seat and lift it off 11 11 Mounting the seat 101988 10 Hook slot of the seat onto screw press the rear downward and at the same time push it forward Push locking pin into lock housing and pus...

Page 78: ...601882 10 Main work Remove screws Take off air filter box top 601880 10 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never operate the vehicle wit...

Page 79: ...lush against the air filter box along the entire sealing sur face If the air filter is not correctly mounted dust and dirt can enter the engine and cause damage Hook air filter box top into the front...

Page 80: ...heir grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil...

Page 81: ...ccidents Danger caused by incorrect chain tension If the chain is too taut the components of the secondary power transmission chain engine sprocket rear sprocket bearings in the transmission and in th...

Page 82: ...from the chain sliding guard and determine the chain tension Info The upper chain section must be taut Chain wear is not always even Repeat this measurement at different chain posi tions Chain tensio...

Page 83: ...bearings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme case...

Page 84: ...ition relative to the reference marks The rear wheel is then correctly aligned Info The upper chain section must be taut Chain wear is not always even Repeat this measurement at different chain posi t...

Page 85: ...per section of the chain with the specified weight Guideline Weight of chain wear measurement 15 kg 33 lb Measure distance of 18 chain links in the lower chain section Info Chain wear is not always ev...

Page 86: ...r edge of the chain pins is in line with or below the chain sliding guard Replace the chain sliding guard x Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tigh...

Page 87: ...nge the chain sliding piece x Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1...

Page 88: ...of the rear wheel stand p 71 11 19 Adjusting basic position of clutch lever Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar Turn the adjusti...

Page 89: ...he 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 B...

Page 90: ...or recommended by KTM Service work and repairs must be performed properly Your authorized KTM workshop will be glad to help The ABS is a safety system that prevents locking of the wheels when driving...

Page 91: ...ar wheels differ greatly under extreme riding conditions for example when making wheelies or if the rear wheel spins This causes the ABS to switch off To reenable the ABS the vehicle must be stopped a...

Page 92: ...ar brake discs in several places to ensure that it conforms to measurement Info Wear reduces the thickness of the brake disc at the contact surface of the brake disc Brake discs wear limit Front 4 0 m...

Page 93: ...e fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help 102010 10 Move the brake fluid reservoir mounted on the handlebar to a horizonta...

Page 94: ...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 sh...

Page 95: ...12 6 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 gla...

Page 96: ...n the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to over heating Adjust the free travel on foot brake lever according to specifications 402027 10 Move th...

Page 97: ...tions 101991 10 Loosen fitting on foot brake cylinder To adjust the basic position of the foot brake lever individually loosen nut and turn screw accordingly Info The range of adjustment is limited Th...

Page 98: ...d Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help 101992 10 Stand the vehicle upright Check the brake fluid level...

Page 99: ...fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil g...

Page 100: ...11 Checking the rear 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 t...

Page 101: ...nings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings x Check the brake linings for damage and cracking If there is w...

Page 102: ...e disc Pull the brake caliper carefully back from the brake disc and hang it to one side Info Do not pull the handbrake lever when the brake caliper is removed 101996 10 Loosen screw and screws Unscre...

Page 103: ...ke discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary 101998 11 Main work Check the wheel bearing for damage and wear If the wheel bearing is dam...

Page 104: ...rew Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake caliper and check that the brake linings are seated correctly Position spacers Mount screws but do not tighten Operate the...

Page 105: ...Screw fork stub M8 15 Nm 11 1 lbf ft Finishing work Take the motorcycle off of the rear wheel stand p 71 13 3 Removing rear wheel x Preparatory work Raise the motorcycle with the rear wheel stand p 70...

Page 106: ...ake discs are not dam aged Take the rear wheel out of the swing arm Info Do not operate the foot brake when the rear wheel is removed 13 4 Installing the rear wheel x Warning Danger of accidents Reduc...

Page 107: ...move bushing Clean and grease the roll surfaces of the bushing and the shaft seal ring Long life grease p 185 Mount the bushing Clean and grease the threads of the wheel spindle and nut Long life grea...

Page 108: ...x1 5 90 Nm 66 4 lbf ft Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Insert wheel speed sensor into the hole Mount an...

Page 109: ...l rubber dampers in the rear hub 102005 10 Lay the rear wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub To check play hold the rear wheel tight and t...

Page 110: ...ncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Warning Danger of...

Page 111: ...08 in If the tread depth is less than the minimum permissible depth Change the tires Check the age of the tires Info The tire s date of manufacture is usually part of the tire markings and is indi cat...

Page 112: ...inertia of these wheels are smaller than in conventional spoke wheels with a tube This results in better handling and riding comfort The rigid rim design results in a spoke wheel that is almost entir...

Page 113: ...t meet specifications Correct tire pressure Mount the protection cap 13 9 Checking the spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that the spoke...

Page 114: ...cy 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 sp...

Page 115: ...attery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rins...

Page 116: ...rical components and safety devices can be damaged The vehi cle is therefore no longer roadworthy 14 2 Installing the battery x B01975 11 Main work Insert the battery into the battery compartment with...

Page 117: ...ttery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Ke...

Page 118: ...r steadily The charging level and the method of charging are very important for the service life of the battery Rapid recharging with a high charging current shortens the battery s service life If the...

Page 119: ...ternator With this device you cannot overcharge the battery Info Never remove lid Charge the battery with a maximum of 10 of the capacity specified on the bat tery housing Switch off and disconnect th...

Page 120: ...Use only fuses with the prescribed amperage Never by pass or repair fuses Info The main fuse protects all power consumers in the vehicle It is in the housing of the starter relay next to the battery...

Page 121: ...eded Check the functioning of the electrical equipment Mount the protection covers Finishing work Mount the seat p 75 Set the clock p 32 14 5 Changing the ABS fuses Warning Fire hazard The electrical...

Page 122: ...B01979 10 To change the fuse of the ABS hydraulic unit Take off protection cap and remove the fuse Insert a new fuse Fuse 58011109115 Mount the protection cap B01979 11 To change the fuse of the ABS...

Page 123: ...vidual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat Preparatory work Switch off all power consumers and switch off the engine Remove t...

Page 124: ...ht license plate lamp Fuse 7 10 A for auxiliary equipment permanent positive Fuse 8 10 A for supplementary equipment accessories connected with ignition switch Fuse 9 10 A ABS Fuse 10 not used Fuse SP...

Page 125: ...ers Close the fuse box cover Finishing work Mount the seat p 75 14 7 Removing the headlight mask with the headlight Preparatory work Switch off all power consumers and switch off the engine 102025 10...

Page 126: ...sconnect the connectors of turn signals and headlight Remove the headlight mask 14 8 Installing the headlight mask with the headlight 102026 11 Main work Connect the connectors of headlight and turn s...

Page 127: ...oth from the fender and position the headlight mask Holding lugs reach into the headlight mask 102028 10 Position groove on counterpiece 102025 11 Position brake line guides Mount and tighten screws G...

Page 128: ...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 Preparatory work Switch off all power consumers and switch...

Page 129: ...onnector Finishing work Install the headlight mask with the headlight p 124 Check the headlight setting p 130 14 10 Changing the parking light bulb Note Damage to reflector Reduced brightness Grease o...

Page 130: ...ctor Pull parking light bulb out of the bulb socket Insert a new parking light bulb in the bulb socket Parking light W5W socket W2 1x9 5d p 174 Insert the bulb socket in the reflector Insert the prote...

Page 131: ...ass forward 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 touch the reflector with your fingers an...

Page 132: ...distance in front of the wall Guideline Distance 5 m 16 ft The rider with luggage and a passenger if applicable now sits down on the motorcycle Switch on the low beam Check the headlight setting For a...

Page 133: ...light and dark must be exactly on the lower mark for a motor cycle with a rider instructions on how to apply the mark Checking the headlight set ting Info Turn clockwise to increase the headlight rang...

Page 134: ...re without causing any malfunctions 125 C 257 F 400407 10 Cooling takes place by means of the air stream and a radiator fan which is controlled by a thermoswitch The lower the speed the less the cooli...

Page 135: ...Keep coolant out of reach of children Condition Engine is cold 102014 10 Stand the motorcycle on its side stand on a horizontal surface Remove the cap of compensating tank Check antifreeze of coolant...

Page 136: ...pecifications Correct the coolant level and find out the cause of the loss Alternative 1 Coolant p 181 Alternative 2 Coolant mixed ready to use p 181 Mount the radiator cap 15 3 Checking the coolant l...

Page 137: ...reach of children Condition Engine is cold 102014 10 Stand the motorcycle on its side stand on a horizontal surface Check the coolant level in the compensating tank The coolant level must be within th...

Page 138: ...lant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immedi ately and contact a physician Immediatel...

Page 139: ...ysician Immediately clean contaminated areas on the skin with soap and water If coolant is swallowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out...

Page 140: ...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 run it u...

Page 141: ...Soft Set the adjusting wheel to position 1 Soft reduced homologated peak performance for better driveability Set the Map Select switch to Advanced Set the adjusting wheel to position 2 Advanced homolo...

Page 142: ...hift lever 0 0 0 A A 400692 10 Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the shift lever Distance between shift lever and upper edge of b...

Page 143: ...ever on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle components during the...

Page 144: ...ng temperature Preparatory work Stand the motorcycle upright on a horizontal surface C00182 10 Main work Check the engine oil level Info After switching off the engine wait one minute before checking...

Page 145: ...aining the 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 imme...

Page 146: ...the oil drain plug with a magnet Mount the oil drain plug with the magnet and seal ring and tighten it Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft 17 4 Removing the oil filter x Wa...

Page 147: ...work Place a suitable container under the engine 102020 10 Main work Remove screws Remove the oil filter cover with the O ring Pull oil filter out of the oil filter housing Circlip pliers reverse 5101...

Page 148: ...ng and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid et...

Page 149: ...l Thoroughly clean the parts and sealing area 100207 10 Position oil screen with the O rings Mount and tighten screw plug with the O ring Guideline Plug oil screen M20x1 5 15 Nm 11 1 lbf ft 100208 10...

Page 150: ...l filter cover M5x16 6 Nm 4 4 lbf ft 17 7 Filling up with engine oil x Info Too little engine oil or poor quality engine oil results in premature wear to the engine 0 0 1 401955 10 Main work Remove fi...

Page 151: ...at it is oil tight Finishing work Check the engine oil level p 142 17 8 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the engine 0 0 1 401955 10...

Page 152: ...sult 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 extra...

Page 153: ...uel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info If you clean the motorcycle regularly its value and appearance will be maintained over a long period Avo...

Page 154: ...ke system to evaporate Push back the protection covers of the handlebar controls to allow any water that has penetrated to evaporate After the motorcycle has cooled off lubricate all moving parts and...

Page 155: ...ould enhance the corrosive effects of salt 401060 01 Clean the motorcycle p 151 Clean the brake system Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with c...

Page 156: ...18 CLEANING CARE 154 Clean the chain p 78...

Page 157: ...om children Info If you want to garage the motorcycle for a longer period take the following actions Before storing the motorcycle check all parts for function and wear If service repairs or replaceme...

Page 158: ...e Raise the motorcycle with the rear wheel stand p 70 Raise the motorcycle with the front wheel stand p 71 Cover the motorcycle with a tarp or cover that is permeable to air Info Do not use non porous...

Page 159: ...Take the motorcycle off of the front wheel stand p 72 Take the motorcycle off of the rear wheel stand p 71 Recharge the battery x p 115 Install the battery x p 114 Set the clock p 32 Perform checks a...

Page 160: ...r to neutral Engine turns but does not start Operating error Carry out the start procedure p 47 Fuse 3 blown Change the fuses of individual power consumers p 121 Coupling of fuel hose connection not c...

Page 161: ...Engine dies during the journey Lack of fuel Refuel p 56 Fuse 1 2 or 3 blown Change the fuses of individual power consumers p 121 The ABS warning lamp lights up The ABS fuse is blown Change the ABS fus...

Page 162: ...rged Ignition not switched off when vehicle was parked Recharge the battery x p 115 Battery is not charged by alternator Check the charging voltage x Check the quiescent current x Combination instrume...

Page 163: ...arning lamp MIL 12 FI warning lamp MIL flashes 1x long 2x short Error level condition Engine coolant temperature sensor input signal too low Engine coolant temperature sensor input signal too high Bli...

Page 164: ...Error level condition Lambda sensor cylinder 1 sensor 1 circuit fault Blink code FI of warning lamp MIL 22 FI warning lamp MIL flashes 2x long 2x short Error level condition Gear position sensor circ...

Page 165: ...der 1 circuit fault Blink code FI of warning lamp MIL 37 FI warning lamp MIL flashes 3x long 7x short Error level condition Ignition coil 1 cylinder 1 circuit fault Blink code FI of warning lamp MIL 3...

Page 166: ...Error Blink code FI of warning lamp MIL 06 FI warning lamp MIL flashes briefly 6x Error level condition Throttle position sensor circuit A input signal too high Throttle position sensor circuit A inpu...

Page 167: ...lerator position sensor circuit B input signal too high Blink code FI of warning lamp MIL 87 FI warning lamp MIL flashes 8x long 7x short Error level condition Accelerator position sensor circuit A an...

Page 168: ...nk code FI of warning lamp MIL 94 FI warning lamp MIL flashes 9x long 4x short Error level condition DBW stop function system error stop function A system error Blink code FI of warning lamp MIL 95 FI...

Page 169: ...diameter exhaust 34 mm 1 34 in Valve play cold 0 07 0 13 mm 0 0028 0 0051 in Crankshaft bearing 2 roller bearings Conrod bearing Needle bearing Piston pin bearing Piston pin with DLC coating Pistons F...

Page 170: ...ing permanent circulation of coolant by water pump Starting aid Electric starter automatic decompressor 22 2 Engine tightening torques Screw membrane fixation M3 2 Nm 1 5 lbf ft Loctite 243 Hose clamp...

Page 171: ...t M6 10 Nm 7 4 lbf ft Loctite 243 Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch slave cylinder M6x20 10 Nm 7 4 lbf ft Loctite 243 Screw clutch slave cylinder M6x35 10 Nm 7 4 lbf ft Screw cranksh...

Page 172: ...ew plug crankshaft clamp M8 20 Nm 14 8 lbf ft Stud exhaust flange M8 10 Nm 7 4 lbf ft Loctite 243 Cylinder head screw M10 Tightening sequence Tighten diagonally beginning with the rear screw on the ti...

Page 173: ...e 243 Engine case stud M16x1 5 25 Nm 18 4 lbf ft Loctite 243 Rotor nut M18x1 5 100 Nm 73 8 lbf ft Nut engine sprocket M20x1 5 80 Nm 59 lbf ft Loctite 243 Nut inner clutch hub M20x1 5 100 Nm 73 8 lbf f...

Page 174: ...Lattice frame made of chrome molybdenum steel tubing powder coated Fork WP Suspension 4860 ROTA SPLIT Shock absorber WP Suspension 4618 with Pro Lever deflector Suspension travel Front 215 mm 8 46 in...

Page 175: ...eering head angle 63 Wheelbase 1 480 15 mm 58 27 0 59 in Seat height unloaded 890 mm 35 04 in Ground clearance unloaded 270 mm 10 63 in Weight without fuel approx 144 kg 317 lb Maximum permissible fro...

Page 176: ...AU15s 12 V 10 W Brake tail light LED License plate lamp W5W socket W2 1x9 5d 12 V 5 W 22 6 Tires Front tires Rear tires 120 70 R 17 M C 58H TL Continental Conti Attack SM 160 60 R 17 M C 69H TL Contin...

Page 177: ...Medium standard 5 3 N mm 30 3 lb in Air chamber length 110 20 30 mm 4 33 0 79 1 18 in Fork length 895 mm 35 24 in Fork oil per fork leg 625 ml 21 13 fl oz Fork oil SAE 4 48601166S1 p 183 22 8 Shock a...

Page 178: ...standard 80 N mm 457 lb in Hard 85 N mm 485 lb in Spring length 220 mm 8 66 in Gas pressure 10 bar 145 psi Static sag 20 25 mm 0 79 0 98 in Riding sag 70 80 mm 2 76 3 15 in Fitted length 395 mm 15 55...

Page 179: ...t Screw cable on starter motor M5 3 Nm 2 2 lbf ft Screw electrical holder M5 3 Nm 2 2 lbf ft Screw exhaust heat shield M5 8 Nm 5 9 lbf ft Loctite 243 Screw fuel hose clamp on fuel tank M5 5 Nm 3 7 lbf...

Page 180: ...diator bracket M6 8 Nm 5 9 lbf ft Screw magnetic holder on side stand M6 6 Nm 4 4 lbf ft Loctite 243 Screw radiator guard M6 8 Nm 5 9 lbf ft Screw rear brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Scre...

Page 181: ...M8 12 Nm 8 9 lbf ft Copper paste Screw main silencer holder M8 25 Nm 18 4 lbf ft Screw main silencer holder on fuel tank M8 25 Nm 18 4 lbf ft Screw rear footrest bracket M8x16 25 Nm 18 4 lbf ft Screw...

Page 182: ...tite 243 Screw swingarm pivot M12 80 Nm 59 lbf ft Lambda sensor M12x1 25 25 Nm 18 4 lbf ft Copper paste Nut linkage lever on swingarm M14x1 5 100 Nm 73 8 lbf ft Nut linkage lever to rocker arm M14x1 5...

Page 183: ...astrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant even in countries with high temperatures Using inferior antifreeze can result in corrosi...

Page 184: ...ntainer and that possess the corresponding properties Synthetic engine oil Recommended supplier Motorex Cross Power 4T Engine oil SAE 10W 50 Standard classification JASO T903 MA p 187 SAE p 187 SAE 10...

Page 185: ...draulic oil that complies with the specified standard see specifications on the container and that possesses the corre sponding properties Recommended supplier Motorex Hydraulic Fluid 75 Shock absorbe...

Page 186: ...aded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or...

Page 187: ...Chain Clean Chain lube for road use Guideline Recommended supplier Motorex Chainlube Road Fuel additive Recommended supplier Motorex Fuel Stabilizer Long life grease Recommended supplier Motorex Bike...

Page 188: ...ex Moto Polish Shine Preserving materials for paints metal and rubber Recommended supplier Motorex Moto Protect Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommend...

Page 189: ...vice intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated wit...

Page 190: ...r brake adding 96 Brake fluid level checking the brake fluid level of front brake 91 rear brake checking 96 Brake linings front brake checking 93 rear brake checking 98 Brakes 52 Braking 52 C Capacity...

Page 191: ...F display 35 Coolant draining 136 Coolant level checking 132 134 Cooling system 132 filling bleeding 137 Customer service 14 E Electric starter button 26 Emergency OFF switch 26 Engine running in 43 E...

Page 192: ...ails 38 Headlight light range adjusting 130 Headlight bulb changing 126 Headlight mask with headlight installing 124 removing 123 Headlight setting checking 130 Horn button 24 I Ignition lock 27 Inten...

Page 193: ...king 106 Rear sprocket checking 82 Rear wheel installing 104 removing 103 Riding 49 starting off 49 S Safe operation 10 Seat mounting 75 removing 75 Seat release 38 Service 13 Service schedule 59 61 S...

Page 194: ...ques 168 fork 174 shock absorber 175 tires 174 Throttle grip 24 Tire air pressure checking 110 Tire condition checking 108 Transport 55 Troubleshooting 158 160 Tubeless tire system 110 Turn signal swi...

Page 195: ...3213104en 3213104en 12 2013 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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