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KTM 690 SMC R, Owner'S Manual

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KTM 690 SMC R Owner'S Manual Download Page 95

12

BRAKE SYSTEM

93

102011-10

–

Remove screws

.

–

Remove cover

with membrane

.

–

Add brake fluid to level

.

Guideline

Measurement of

5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 (

p. 183)

–

Position the cover with the membrane. Mount and tighten the screws.

Info

Clean up overflowed or spilt brake fluid immediately with water.

12.6

Checking the front brake linings

Warning

Danger of accidents

 

Reduced braking efficiency caused by worn brake linings.

–

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. The braking effect is greatly
reduced and the brake discs are destroyed. Check the brake linings regularly.

Summary of Contents for 690 SMC R

Page 1: ...OWNER S MANUAL 2016 690 SMC R Art no 3213394en...

Page 2: ......

Page 3: ...viations resulting from continuing development and design can however not be completely excluded All specifications are non binding KTM Sportmotorcycle GmbH specifically reserves the right to modify o...

Page 4: ...SO 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 T V Man...

Page 5: ...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 article number 22 6 CONTROLS 23 6 1 Clutch lever 23 6 2 Hand brake lever 23 6 3 Throttle grip 24...

Page 6: ...usting 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 68 11 SE...

Page 7: ...3 9 Checking the spoke tension 111 14 ELECTRICAL SYSTEM 113 14 1 Removing the battery 113 14 2 Installing the battery 115 14 3 Recharging the battery 117 14 4 Changing the main fuse 120 14 5 Changing...

Page 8: ...9 20 TROUBLESHOOTING 160 21 BLINK CODE 163 22 TECHNICAL DATA 169 22 1 Engine 169 22 2 engine tightening torques 170 22 3 capacities 173 22 3 1 Engine oil 173 22 3 2 Coolant 174 22 3 3 Fuel 174 22 4 Ch...

Page 9: ...th this symbol requires specialist knowledge and technical understanding In the interest of your own safety have these jobs performed by an authorized KTM workshop There your motorcycle will be optima...

Page 10: ...document are explained below Specific name Identifies a proprietary name Name Identifies a protected name Brand Identifies a brand available on the open market Underlined terms Refer to technical det...

Page 11: ...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 12: ...Warning Indicates 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 pro...

Page 13: ...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 14: ...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 15: ...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 16: ...ironmental 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 Use operating and auxiliary substances such as...

Page 17: ...inspect or replace parts before the next scheduled service It is imperative that you adhere to the stipulated run in times and service intervals If you observe these exactly you will ensure a much lo...

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 H01049 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: ...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 article number 402025 10 The shock absorber article number is on the left side of...

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: ...gnition ON In this position the ignition circuit is closed and the engine can be started Steering locked In this position the ignition circuit is interrupted and the steering locked The ignition key c...

Page 30: ...DO trip master 1 TRIP 1 and trip mas ter 2 TRIP 2 Press the SET button to reset the trip master 1 function TRIP 1 and trip master 2 func tion TRIP 2 to 0 0 The ABS can be switched off with button 6 10...

Page 31: ...blue The high beam is 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...

Page 32: ...up for one second as a function check 400881 01 LEnGth After the display function check the wheel circumference LEnGth is displayed for one sec ond Info The number 1870 mm equals the circumference of...

Page 33: ...s shown in kilometers per hour km h or in miles per hour mph 6 10 7 Setting the kilometers or miles Info If the unit is changed the value is retained and converted accordingly Make the setting accordi...

Page 34: ...O display 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 The time m...

Page 35: ...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 even if...

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: ...ways 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 ove...

Page 39: ...ground or the sewage system 101975 10 Lift 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 breat...

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: ...trip read the entire Owner s Manual carefully Get to know the controls Adjust the basic position of the clutch lever p 86 Adjust the basic position of the hand brake lever p 89 Adjust the basic positi...

Page 46: ...andling 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...

Page 47: ...t be burned or singed by the hot exhaust system If you carry luggage make sure you secure it firmly as close as possible to the center of the vehicle and ensure even weight distribu tion between the f...

Page 48: ...d 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 136 Check the chain for dirt p 78 Check the chain tension p...

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: ...e is 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...

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: ...ar release the clutch lever 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 u...

Page 54: ...om the flash rhythm you can deduce a two digit number the so called blink code The blink code tells you which component is affected by a malfunction 8 5 Applying the brakes Warning Danger of accidents...

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

Page 56: ...persons Never leave the vehicle unattended 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 War...

Page 57: ...lock power continues to flow to most power consumers This discharges the battery You should therefore always switch off the engine with the ignition key the emergency OFF switch is intended for emerge...

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: ...incorrect routing Check the antifreeze and coolant level p 134 Check the cables for damage and routing without sharp bends Change the air filter Clean the air filter box Check the fuel pressure Check...

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

Page 64: ...ot change 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...

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

Page 66: ...when riding over an asphalt edge the rear wheel suspension compresses quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses s...

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: ...0 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 10 8 Handlebar position 601874 10 On the upper triple clamp there are two holes at a distance of to each other...

Page 70: ...s Remove screws Remove the handlebar support Place the handlebar support in the required position Mount and tighten screws Guideline Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Info Posi...

Page 71: ...on a firm and even surface 401942 01 Raise the motorcycle in the area of the footrest bracket Lift stand 78929955100 Neither wheel is in contact with the ground Secure the motorcycle against falling o...

Page 72: ...ith 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 402346 01 Insert the adapter into the rear wheel stand...

Page 73: ...on a firm and even surface 401943 10 Secure the motorcycle against falling over Remove the rear wheel stand and lean the vehicle on side stand 11 5 Raising the motorcycle with the front wheel stand N...

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: ...nd 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 brake cleaner...

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 with...

Page 79: ...ush 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 o...

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: ...rom the wheel stand p 71 11 16 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain is too taut the components of the secondary power transmissi...

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: ...position relative to 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 ti...

Page 85: ...aced together 1 2 3 16 17 18 0 0 0 B B 0 0 A A 400987 10 Pull at the top part of the chain with the specified weight Guideline Weight of chain wear measurement 15 kg 33 lb Measure distance of 18 chain...

Page 86: ...r engine sprocket 401170 01 Check the chain sliding guard for wear If the lower edge of the chain pins is in line with or below the chain sliding guard Replace the chain sliding guard Check that the c...

Page 87: ...he chain sliding piece Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the screw on the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm...

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

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: ...ains spare parts and tires that have been approved and 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 s...

Page 91: ...ht up if the rotating speeds of the front and rear 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 T...

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: ...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 the...

Page 97: ...cifications 101991 10 Loosen fittings 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 lim...

Page 98: ...uid 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 lev...

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

Page 102: ...ake disc Pull the brake caliper carefully back from the brake disc and hang it to one side Info Do not pull the hand brake lever while the brake caliper is removed 101996 10 Loosen screw and screws Un...

Page 103: ...the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary H00935 10 Main work Check the wheel bearing for damage and wear If the wheel bearing...

Page 104: ...6 Nm 4 4 lbf ft Position the brake caliper on the brake disc The brake linings are correctly positioned Position spacers Mount screws but do not tighten yet Operate the hand brake lever repeatedly un...

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

Page 106: ...amaged brake disc Always lay the wheel down in such a way that the brake disc is not damaged Take the rear wheel out of the swingarm Info Do not operate the foot brake when the rear wheel is removed 1...

Page 107: ...Replace the wheel bearing Remove spacer Clean and grease shaft seal ring and contact surface of the spacer Long life grease p 186 Insert the spacer Clean and grease the thread of the wheel spindle an...

Page 108: ...5x1 5 90 Nm 66 4 lbf ft Position the wheel speed sensor in the drill hole Mount and tighten screw Guideline Screw wheel speed sensor M6 6 Nm 4 4 lbf ft Operate the foot brake lever repeatedly until th...

Page 109: ...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 try to turn the rear...

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: ...ncy 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 s...

Page 115: ...ttery 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 rinse...

Page 116: ...able and positive cable from the battery S00621 10 Remove screws Pull retaining bracket of the battery forward and remove it Lift the battery up and out Info Never operate the motorcycle with a discha...

Page 117: ...ment with the terminals facing rearward Battery YTZ10S p 175 Position retaining bracket and mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft S00623 10 Position washer po...

Page 118: ...ve terminal cover Position washer and negative cable and mount and tighten the screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft S00624 10 Position EFI control unit Mount battery cover Fini...

Page 119: ...of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Warning Environmental hazard The battery contains elements that are harmful to the environmen...

Page 120: ...are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If...

Page 121: ...th 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 the battery charger after ch...

Page 122: ...d Use only fuses with the prescribed amperage Never bypass 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 123: ...eeded 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 124: ...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 125: ...dividual 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...

Page 126: ...ght license plate lamp Fuse 7 10 A for auxiliary equipment permanent positive Fuse 8 10 A for auxiliary equipment accessories connected with ignition switch Fuse 9 10 A ABS Fuse 10 not assigned Fuse S...

Page 127: ...ctioning properly 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 eng...

Page 128: ...rs for the turn signals and for the headlight Remove the headlight mask 14 8 Installing the headlight mask with the headlight 102026 11 Main work Connect plug in connectors of the headlight and of the...

Page 129: ...oth from the fender and position the headlight mask Holding lugs engage in the headlight mask 102028 10 Position groove on counterpiece 102025 11 Position brake line guides Mount and tighten screws Gu...

Page 130: ...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 switc...

Page 131: ...ector Finishing work Install the headlight mask with the headlight p 126 Check the headlight setting p 132 14 10 Changing the parking light bulb Note Damage to reflector Reduced brightness Grease on t...

Page 132: ...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 176 Insert the bulb socket in the reflector Insert the prote...

Page 133: ...and take it off Press the turn signal bulb lightly 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 and keep it free...

Page 134: ...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 135: ...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 136: ...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 137: ...is contaminated with coolant 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 tan...

Page 138: ...le operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system...

Page 139: ...eck the coolant level in the radiator The radiator must be completely filled If the coolant level does not meet specifications Correct the coolant level and find out the cause of the loss Coolant p 18...

Page 140: ...t Place a suitable container under the engine Remove screw Remove the radiator cap Completely drain the coolant Mount and tighten screw with a new seal ring Guideline Plug drain hole of water pump M10...

Page 141: ...orizontal surface Remove radiator cap 102017 10 Refill the coolant Coolant p 183 Fill the radiator completely with coolant Mount radiator cap 102018 10 Remove the cap from compensating tank and add co...

Page 142: ...and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and run it until the 5th bar of the temperature indicator lights up Switch off t...

Page 143: ...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 144: ...must not touch the rider s boot when in the basic position When the shift lever keeps touching the boot the transmission will be subject to an excessive load 0 0 0 A A 400692 10 Sit on the vehicle in...

Page 145: ...h of the shift lever and shift shaft Mount shift lever on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into con...

Page 146: ...ting 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 checkin...

Page 147: ...gine oil 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 lu...

Page 148: ...the oil drain plug with 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 Warnin...

Page 149: ...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 510...

Page 150: ...g and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc...

Page 151: ...roughly 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 Posit...

Page 152: ...oil filter cover M5x16 6 Nm 4 4 lbf ft 17 7 Filling up with engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the engine 102023 10 Main work Remove filler...

Page 153: ...s oil tight Finishing work Check the engine oil level p 144 17 8 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear of the engine 102023 10 Main work Rem...

Page 154: ...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 155: ...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 156: ...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 157: ...ould enhance the corrosive effects of salt 401060 01 Clean the motorcycle p 153 Clean the brake system Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with c...

Page 158: ...18 CLEANING CARE 156 Clean the chain p 78...

Page 159: ...ay from 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 repl...

Page 160: ...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 161: ...Take the motorcycle off of the front wheel stand p 72 Remove the rear of the motorcycle from the wheel stand p 71 Recharge the battery p 117 Install the battery p 115 Set the clock p 32 Perform checks...

Page 162: ...al The vehicle is in gear and the side stand is folded out Shift gear to neutral Engine turns but does not start Operating error Carry out the start procedure p 47 Fuse 3 blown Change the fuses of ind...

Page 163: ...oling system Fill bleed the cooling system p 138 FI warning lamp MIL lights flashes Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool Engine dies during the jou...

Page 164: ...orrectly displayed Fuse 1 blown Change the fuses of individual power consumers p 123 Set the clock p 32 Battery discharged Ignition not switched off when vehicle was parked Recharge the battery p 117...

Page 165: ...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 166: ...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 167: ...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 168: ...Blink code FI of warning lamp MIL 82 FI warning lamp MIL flashes 8x long 2x short Error level condition Throttle position sensor circuit A input signal too high Throttle position sensor circuit A inpu...

Page 169: ...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 170: ...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 171: ...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 172: ...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 173: ...0 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 Loctite 243 Screw c...

Page 174: ...ankshaft clamp screw plug M8 15 Nm 11 1 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 t...

Page 175: ...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 176: ...enum steel tubing powder coated Fork WP Performance Systems 4860 ROTA SPLIT Shock absorber WP Performance Systems 4618 with Pro Lever linkage Suspension travel Front 215 mm 8 46 in Rear 250 mm 9 84 in...

Page 177: ...heelbase 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 front axle load 150 kg 33...

Page 178: ...l 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 Continental Conti Attack SM Add...

Page 179: ...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 184 22 8 shock absorber Shock absorber...

Page 180: ...57 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 in Shock absorber...

Page 181: ...bination switch left M5 3 5 Nm 2 58 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 ft Scr...

Page 182: ...14 Nm 10 3 lbf ft Loctite 243 Screw ignition lock M6 10 Nm 7 4 lbf ft Loctite 243 Screw lower radiator bracket M6 8 Nm 5 9 lbf ft Screw magnetic holder on side stand M6 6 Nm 4 4 lbf ft Loctite 243 Scr...

Page 183: ...M8x12 5 Nm 3 7 lbf ft Loctite 243 Screw license plate holder top M8 20 Nm 14 8 lbf ft Screw main silencer clamp M8 12 Nm 8 9 lbf ft Copper paste Screw main silencer holder M8 25 Nm 18 4 lbf ft Screw m...

Page 184: ...rew front brake caliper M10x1 25 45 Nm 33 2 lbf ft Loctite 243 Screw swingarm pivot M12 80 Nm 59 lbf ft Lambda sensor M12x1 25 25 Nm 18 4 lbf ft Copper paste Nut linkage lever on swingarm M14x1 5 100...

Page 185: ...UID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Only use high quality coolant with corrosion inhibitor for aluminum motors even in countries with high temperatures Using inferior antifre...

Page 186: ...fication JASO T903 MA p 188 SAE p 188 SAE 10W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properti...

Page 187: ...ification SAE p 188 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corresponding proper ties Super unleaded ROZ 95 RO...

Page 188: ...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 189: ...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 190: ...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 191: ...ng of the wheels when driving straight ahead without the influence of lateral forces MIL Malfunction indicator lamp Indicator lamp that supports vehicle diagnostics through flash codes OBD On board di...

Page 192: ...27 LIST OF ABBREVIATIONS 190 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 193: ...ols indicate an error condition that requires prompt intervention Active driving aids are also represented by yellow or orange symbols The low fuel warning lamp lights up yellow The fuel level has rea...

Page 194: ...28 LIST OF SYMBOLS 192 The idling speed indicator lamp lights up green The transmission is shifted to idle The high beam indicator lamp lights up blue The high beam is switched on...

Page 195: ...rear brake adding 96 Brake fluid level front brake checking 91 rear brake checking 96 Brake linings front brake checking 93 rear brake checking 98 Brakes 52 C Capacity Coolant 174 engine oil 150 173...

Page 196: ...ecking 134 136 Cooling system 134 filling bleeding 138 Customer service 15 E Electric starter button 26 Emergency OFF switch 26 Engine running in 43 Engine characteristic adjusting 141 Engine number 2...

Page 197: ...bulb changing 128 Headlight mask with headlight installing 126 removing 125 Headlight setting checking 132 Horn button 24 I Ignition lock 27 Implied warranty 14 Intended use 9 K Key number 21 L Light...

Page 198: ...2 Rear wheel installing 104 removing 103 Riding 49 starting off 49 S Safe operation 11 Seat mounting 75 removing 75 Seat release 38 Service 15 Service schedule 59 61 Shift lever 39 basic position adju...

Page 199: ...k 176 shock absorber 177 Tires 176 Throttle grip 24 Tire air pressure checking 110 Tire condition checking 108 Transport 55 Troubleshooting 160 162 Tubeless tire system 110 Turn signal switch 25 Type...

Page 200: ...3213394en 3213394en 09 2015 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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