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KTM 690 SMC USA 2010, Owner'S Manual, Page: 85 / 196

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KTM 690 SMC USA 2010 Owner'S Manual Download Page 85

MAINTENANCE WORK ON CHASSIS AND ENGINE

83

9.28

Checking the chain, rear sprocket and engine sprocket

100132-10

–

Check the rear sprocket and engine sprocket for wear.
» If the rear sprocket and engine sprocket are worn:

–

Replace the rear sprocket or engine sprocket.

x

Info

The engine sprocket, rear sprocket and chain should always be replaced
together.

Summary of Contents for 690 SMC USA 2010

Page 1: ...OWNER S MANUAL 2010 690 SMC USA Art no 3211518en...

Page 2: ......

Page 3: ...viations resulting from continuing devel opment and design of our vehicles cannot however be completely excluded All specifications are non binding KTM Sportmotorcycle AG specifically reserves the rig...

Page 4: ...s is permitted only with the express written permission of the copyright owner ISO 9001 12 100 6061 According to the international quality management standard ISO 9001 KTM uses quality assurance proce...

Page 5: ...n instrument indicator lamps 32 Combination instrument display 33 Combination instrument speedometer 34 Setting kilometers or miles 34 Combination instrument time 35 Setting the clock 35 Combination i...

Page 6: ...ead bearing play 75 Adjusting play of steering head bearing x 76 Handlebar position 77 Adjusting handlebar position x 78 Checking the chain for dirt 79 Cleaning the chain 79 Checking the chain tension...

Page 7: ...ition of clutch lever 142 Checking rectifying the fluid level of the hydraulic clutch 143 Checking the play in the throttle cable 144 Adjusting the play in the throttle cable x 145 Checking the engine...

Page 8: ...TABLE OF CONTENTS 6 AUXILIARY SUBSTANCES 185 STANDARDS 188 INDEX 189...

Page 9: ...d technical understanding In the interest of your own safety have these jobs done in an authorized KTM workshop There your motorcycle will be serviced optimally by specially trained experts using the...

Page 10: ...wet roads can lead to above average wear of components such as the transmission train or the brakes For this reason it may be necessary to service or replace worn parts before the limit specified in...

Page 11: ...g mounter 59029019000 During assembly non reusable parts e g self locking screws and nuts seals and seal rings O rings pins lock washers must be replaced by new parts If a thread lock e g Loctite is u...

Page 12: ...naturally hope that you will be able to enjoy it to the fullest However it is a potential problem for the environment and can lead to conflicts with other persons But if you use your motorcycle respon...

Page 13: ...IMPORTANT INFORMATION 11...

Page 14: ...IMPORTANT INFORMATION 12 2 1 Overview of warning labels 100330 10...

Page 15: ...a 2 Type label USA 3 Information emission control 4 Information noise emission 5 Information suspension setting 6 Information chain tension 7 Information fuel evaporation system 8 Information putting...

Page 16: ...IMPORTANT INFORMATION 14 100340 01 Type label USA 100847 01 Information emission control...

Page 17: ...IMPORTANT INFORMATION 15 100846 01 Information noise emission 100344 01 Information suspension setting...

Page 18: ...IMPORTANT INFORMATION 16 100338 01 Information chain tension 100848 01 Information fuel evaporation system 700210 01 Information putting into operation...

Page 19: ...and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate mea...

Page 20: ...n investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remady campaign However NHTSA cannot become involved in individual problems between you you...

Page 21: ...er components which conducts exhaust gases 2 Removal or puncturing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving part of the vehicle or parts of the exhaust or i...

Page 22: ...VIEW OF VEHICLE 20 3 1 View of vehicle front left side 100328 10...

Page 23: ...VIEW OF VEHICLE 21 1 Hand brake lever 2 Clutch lever 3 Seat 4 Filler cap 5 Front brake caliper 6 Shift lever 7 Engine number 8 Side stand 9 Footrest 10 Seat release strap...

Page 24: ...VIEW OF VEHICLE 22 3 2 View of vehicle rear right side 100329 10...

Page 25: ...2 Light switch flasher switch horn button 3 Rear mirror 4 Combination instrument 5 Emergency OFF switch electric starter button 6 Throttle grip 7 Rear brake caliper 8 Shock absorber rebound damping 9...

Page 26: ...N OF SERIAL NUMBERS 24 4 1 Chassis number 100217 10 The chassis number is stamped on the steering head on the right 4 2 Type label 100218 10 Type label is located on the upper right frame tube below t...

Page 27: ...10 The key number can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place 4 4 Engine number 600479 10 The engine number is stamped on th...

Page 28: ...NUMBERS 26 4 5 Fork part number 600480 10 The fork part number is stamped on the inner side of the fork stub 4 6 Shock absorber part number 100216 10 The shock absorber part number is on the right of...

Page 29: ...lever is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 5 2 Hand brake lever 600598 11 The hand break lever is fitted on the right side of the handle...

Page 30: ...witched on 5 4 Turn signal switch 100223 10 The turn signal switch is fitted on the left side of the handlebar Possible states Turn signal off Turn signal light left on Turn signal switch pressed to t...

Page 31: ...perated in this position 5 6 Emergency OFF switch 100225 10 The emergency OFF switch is fitted on the right side of the handlebar Possible states Emergency OFF switch off In this position the ignition...

Page 32: ...steering lock 600825 01 The ignition steering lock is located in front of the seat Possible states Ignition OFF In this position the ignition circuit is interrupted a running engine stops and a non r...

Page 33: ...ion buttons Tachometer Indicator lights Display 5 10 Combination instrument function buttons 400833 10 You can change the display mode with the MODE button Possible display modes are distance traveled...

Page 34: ...erating state of the motorcy cle Possible states The turn signal indicator lamp flashes green simultaneously with the turn signal The turn signal is switched on The idle speed indicator lamp lights up...

Page 35: ...mbination instrument display 400836 01 When you switch on the ignition all display segments light up for a second as a function test 400881 01 LEnGth Following the display function test the LEnGth whe...

Page 36: ...speed is shown in kilometers per hour km h or in miles per hour mph 5 15 Setting kilometers or miles Info If you change the unit the value ODO is retained and converted accordingly Making the setting...

Page 37: ...active Keep the MODE button pressed until the display mode changes from km h to mph or from mph to km h 5 16 Combination instrument time 400838 11 The time is shown in area of the display Info The ti...

Page 38: ...on pressed simultaneously The time is set 5 18 Combination instrument display ODO 400839 01 In the ODO display mode the total distance traveled is shown in kilometers or miles Info This value is retai...

Page 39: ...ng TRIP 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...

Page 40: ...F display the fuel warning light switches on 5 22 Combination instrument coolant temperature indicator 700124 01 The temperature display consists of 12 bars The more bars that light up the hotter the...

Page 41: ...sert the ignition key Turn the ignition key 90 counterclockwise and remove the filler cap Info The filler cap has a tank air vent system 5 24 Closing filler cap 100228 01 Put the filler cap back on an...

Page 42: ...rails 100229 10 The handrails are used for moving the motorcycle around When you have a passenger the passenger can hold on the handrails during the journey 5 26 Seat release 100230 10 The seat can be...

Page 43: ...ootrests can be folded up and down Possible states Passenger footrests folded up For operation without a passenger Passenger footrests folded down For operation with a passenger 5 28 Shift lever 60048...

Page 44: ...can be seen in the photograph The neutral or idle position is between the first and second gears 5 29 Foot brake lever 600485 10 Foot brake lever is located in front of the right footrest The rear br...

Page 45: ...c starter system see the riding instruc tions Possible states Side stand folded out The vehicle can be supported on the side stand The safety electric starter system is active Side stand folded in Thi...

Page 46: ...itted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling characteristic due to non approved and or non recommended t...

Page 47: ...basic position of hand brake lever p 87 Adjust the basic position of the foot brake lever x p 97 Get used to handling the vehicle on a suitable piece of land before making a longer trip Try also to r...

Page 48: ...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 49: ...h a way that it cannot be burned or singed by the hot exhaust system If you carry any baggage make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dist...

Page 50: ...chain tension p 80 Clean the chain p 79 Check the tire condition p 111 Check the tire air pressure p 114 Check the front brake fluid level p 88 Check the rear brake fluid level p 98 Check the front b...

Page 51: ...d safety equipment may be damaged Never operate the vehicle with a discharged battery or without a battery Note Engine failure High engine speeds in cold engines have a negative effect on the service...

Page 52: ...a gear is engaged If the side stand is folded out and you shift into gear and release the clutch the engine stops Take the weight off the side stand and swing it back up with your foot as far as it wi...

Page 53: ...gers in your country Warning Danger of accidents Danger of accidents caused by dangerous driving Observe the traffic regulations and ride defensively and with foresight in order to recognize danger as...

Page 54: ...as usual before putting it into operation Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never ride the vehicle without an air filter since dust and...

Page 55: ...nsid erably lower Accelerate only up to a speed suitable for the road surface and weather conditions When traveling in bends do not shift and accelerate very carefully To shift down brake if necessary...

Page 56: ...iding and braking gently Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake Check the brake system and do not continue riding Your authorized...

Page 57: ...but do not overstress the engine In this way you have to brake far less and the brakes do not overheat 7 6 Stopping parking Warning Risk of misappropriation Usage by unauthorized persons Never leave...

Page 58: ...o flow to most power consumers and the battery will discharge You should therefore always switch off the engine with the ignition key the emergency OFF switch is intended for emergencies only Park the...

Page 59: ...into contact with fuel Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Info This m...

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

Page 61: ...eck the free travel of the foot brake lever p 96 Lubricate the linkage of the rear wheel suspension x Check that the shock absorber and fork are leak tight If necessary and depending on use service th...

Page 62: ...ndamaged routed without sharp bends and set correctly Change the air filter Clean the air filter box x Check rectify the fluid level of the hydraulic clutch p 143 Check the screws and nuts for tightne...

Page 63: ...SERVICE PLAN 61 K75A Every 7 500 km 4 660 mi or annually K150A Every 15 000 km 9 321 mi or every 2 years K300A Every 30 000 km 18 641 mi or every 4 years...

Page 64: ...ebar to the straight ahead position Align the work stand to the front with the adapters to the fork legs Front work stand 61029055300 Info Always jack up the rear of the motorcycle first Jack up the f...

Page 65: ...screw it into the link forks Work stand adapter 61029055110 Work stand rear 61029055100 Stand the motorcycle upright align the work stand to the rear and jack up the motorcy cle 9 4 Taking the rear f...

Page 66: ...be the basis of your own personal chassis adaptation Do not change the adjustments at random or by more than 40 since otherwise the riding characteristics could deteriorate particularly at high speed...

Page 67: ...lockwise to reduce suspension damping 9 7 Adjusting rebound damping of fork Info The hydraulic rebound damping determines the fork rebound behavior 100244 10 Turn adjusting screws clockwise until they...

Page 68: ...d and high speed refer to the movement of the shock absorber during compression and not the riding speed of the motorcycle Changes in the settings in the low speed range have an impact on the high spe...

Page 69: ...15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping 9 10 Adjusting the high speed compression damping of the sho...

Page 70: ...mping high speed Comfort 1 5 turns Standard 1 turn Sport 0 5 turn Full payload 0 5 turn Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping 9 11 Adjusting the re...

Page 71: ...icks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping 9 12 Measuring the unloaded rear wheel sag Jac...

Page 72: ...to help you by holding the motorcycle upright Measure the distance between the rear axle and the fixed point again Make a note of the value as measurement Info The static sag is the difference between...

Page 73: ...erson now has to measure the distance between the rear axle and a fixed point Make a note of the value as measurement Info The riding sag is the difference between measurements and Check the riding sa...

Page 74: ...orber clean it thoroughly 700541 01 Loosen locking ring Turn adjusting ring until the spring is no longer under tension Hook wrench T106S Measure the overall spring length without a load Tension the s...

Page 75: ...contact with the ground and the fork legs are no longer under tension Remove the fork protector p 74 600634 10 Push dust boot of both fork legs downwards Info The dust boots should remove dust and co...

Page 76: ...s the dust boots back into their normal position Remove excess oil Install the fork protector p 75 Remove the motorcycle from the work stand 9 18 Removing the fork protector 600633 11 Remove screws an...

Page 77: ...Remaining screws chassis M6 10 Nm 7 4 lbf ft 9 20 Checking the steering head bearing play Warning Danger of accidents Unstable vehicle handling from incorrect steering head bearing play Adjust the st...

Page 78: ...e steering range No resting locations should be noticeable If click positions are noticeable Adjust play of the steering head bearing x p 76 Check the steering head bearing and change if necessary Rem...

Page 79: ...ycle from the work stand 9 22 Handlebar position 0 0 B B 0 0 A A 400271 11 On the upper triple clamp there are 2 holes at a distance to each other Distance between holes 15 mm 0 59 in The holes on the...

Page 80: ...the cables and lines Remove the two screws Remove the handlebar support Place the handlebar support in the required position Fit and tighten the two screws Guideline Screw handlebar support M10 40 Nm...

Page 81: ...s their 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...

Page 82: ...arning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bearings in transmi...

Page 83: ...es not meet specifications Adjust the chain tension p 81 9 27 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the comp...

Page 84: ...ve 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 so you should check this setting at different chain positions...

Page 85: ...procket and engine sprocket 100132 10 Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Replace the rear sprocket or engine sprocket x Info The eng...

Page 86: ...aximum distance at the longest chain section 272 mm 10 71 in If distance is greater than the specified measurement Replace the chain x Info When the chain is replaced the rear sprocket and engine spro...

Page 87: ...hassis M6 10 Nm 7 4 lbf ft 302112 10 Check the chain guide for wear If the chain guide is worn Change the chain guide x Check that the chain guide is firmly seated If the chain guide is loose Tighten...

Page 88: ...s and Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Condition Number of teeth 45 teeth Insert nut in hole Position the chain guide Mount and tighten screws and Guideline Remaining screws chas...

Page 89: ...177 in If the brake disc thickness is less than the specified value Replace the brake disc Check the front and rear brake discs for damage cracks and deformation If damage cracks or deformation are v...

Page 90: ...he brake fluid of the front and rear brakes according to the service schedule Your authorized KTM workshop will be glad to help 600603 10 Move the brake fluid reservoir mounted on the handlebar to a h...

Page 91: ...t and rear brakes according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fu...

Page 92: ...ater 9 34 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 b...

Page 93: ...e Maintenance work and repairs must be carried out professionally Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid conta...

Page 94: ...considerably from the original KTM brake lin ings If brake linings are used that differ from the originals there is no guarantee that they comply with the original license The vehicle no longer corres...

Page 95: ...from the brake fluid reservoir Install the front brake linings x p 94 100254 12 Add brake fluid level to Guideline Measurement of 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 181 Position the cover with th...

Page 96: ...Remove brake linings 100845 10 Remove screws and spacers Remove the brake caliper Clean the brake caliper 9 37 Installing the front brake linings x Warning Danger of accidents Reduced braking efficien...

Page 97: ...om the originals there is no guarantee that they comply with the original license The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid Check the brake dis...

Page 98: ...rake can fail due to over heating 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 contact to the foot...

Page 99: ...g to specifications 600639 10 Remove screws 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...

Page 100: ...brake fluid Change the brake fluid of the front and rear brakes according to the service schedule Your authorized KTM workshop will be glad to help 100258 10 Stand the vehicle upright Check the brake...

Page 101: ...fluid Change the brake fluid of the front and rear brakes according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause e...

Page 102: ...42 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 103: ...Maintenance work and repairs must be carried out professionally Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact...

Page 104: ...differ considerably from the original KTM brake lin ings If brake linings are used that differ from the originals there is no guarantee that they comply with the original license The vehicle no longer...

Page 105: ...luid escapes from the brake fluid reservoir If it does clean it up Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes 100288 10 Remove the saf...

Page 106: ...the screw cap with the membrane Info Clean up overflowed or spilt brake fluid immediately with water 9 44 Removing front wheel x Jack up the rear of the motorcycle p 63 Jack up the front of the motorc...

Page 107: ...ed by damaged brake discs Always lay the wheel down in such a way that the brake disc is not damaged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork 600626 11 R...

Page 108: ...186 Lift the front wheel into the fork position it and insert the wheel spindle Mount and tighten screw Guideline Screw front wheel spindle M24x1 5 40 Nm 29 5 lbf ft Position the brake caliper and che...

Page 109: ...everal times to align the fork legs Fully tighten screws Guideline Screw fork stub M8 15 Nm 11 1 lbf ft Take the rear from the work stand p 63 9 46 Removing rear wheel x Jack up the rear of the motorc...

Page 110: ...of the swing arm Info Do not operate the foot brake when the rear wheel is removed 9 47 Installing the rear wheel x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the b...

Page 111: ...heel in the swingarm and bring the brake disc on the brake caliper into contact 100270 10 Push the rear wheel forward as far as possible and lay the chain on the rear sprocket Mount the wheel spindle...

Page 112: ...l x p 107 600623 10 Check bearing If the bearing is damaged or worn Replace the bearings x Check rubber dampers of the rear hub for damage and wear If the rubber dampers of the rear hub are damaged or...

Page 113: ...Danger of accidents Uncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be u...

Page 114: ...he age of the tires Info The tire s date of manufacture is usually part of the tire markings and is indi cated by the last four digits of the DOT marking The first two digits refer to the week of manu...

Page 115: ...egularly especially on a new motorcycle 400694 01 Briefly strike each spoke with a screwdriver blade Info The frequency of the tone is a function of the spoke length and spoke diameter If you hear dif...

Page 116: ...d moments of 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...

Page 117: ...t 2 0 bar 29 psi Rear 2 0 bar 29 psi Tire air pressure with passenger fully loaded Front 2 0 bar 29 psi Rear 2 2 bar 32 psi If the tire pressure does not meet specifications Correct tire pressure Moun...

Page 118: ...ng the battery x Warning Risk of injury Battery acid and battery gases cause serious cauterization Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid conta...

Page 119: ...battery rack Info Never operate the motorcycle with a discharged battery or without a battery In both cases electrical components and safety devices can be damaged The vehi cle is therefore no longer...

Page 120: ...contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Warning Environmental hazard Battery parts and acid are harmfu...

Page 121: ...oltage and charging time are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must b...

Page 122: ...Never remove lid Charge the battery with a maximum of 10 of the capacity specified on the bat tery housing Switch off and disconnect the charger after charging Guideline The charge current charge volt...

Page 123: ...nsumers and switch off the engine Remove the seat p 115 600604 10 Remove protection covers 600605 10 Use a needle nose plier to remove a defective main fuse Insert the new main fuse Fuse 58011109130 p...

Page 124: ...59 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat Switch off all power consumers and the engine Remove...

Page 125: ...high beam low beam parking light tail light license plate lamp Fuse 8 10A for accessories accessories connected with ignition switch Fuse 9 10A for accessories permanent positive Fuse 10 not used Fus...

Page 126: ...consumer is functioning properly Close the fuse box cover Mount the seat p 116 9 60 Adjusting the engine characteristic Switch off the ignition by turning the ignition key to position OFF Remove the...

Page 127: ...e Map Select switch to Standard Set the adjusting wheel to position 3 4 5 6 7 8 or 9 Standard homologated performance with balanced responsiveness Set the Map Select switch to poor fuel quality Set th...

Page 128: ...296 11 Cover the fender with a cloth to protect it from damage Remove the screws on the left and right Tip the headlight mask forward and pull it off upward 100294 10 Disconnect the connectors of flas...

Page 129: ...the headlight mask with the headlight 100294 11 Connect the connectors of headlight and flasher lights Check lighting function 100295 10 Remove the cloth from the fender attach the headlight mask to...

Page 130: ...ten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 9 63 Changing the headlight bulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be d...

Page 131: ...43t p 173 Fix the headlight bulb in the headlight using the spring bar Replace the rubber cap Attach the connector Install the headlight mask with the headlight p 127 9 64 Changing the parking light b...

Page 132: ...bulb in the bulb socket Parking light W5W socket W2 1x9 5d p 173 Insert the bulb socket in the reflector Insert the rubber cap Install the headlight mask with the headlight p 127 9 65 Changing the re...

Page 133: ...rt a new bulb and turn it clockwise as far as possible Brake tail light P21 5W socket BAY15d p 173 Check the function of the rear lamp and the brake light Check that the seal is correctly seated Posit...

Page 134: ...until it stops Flasher light RY10W socket BAU15s p 173 Position the diffuser Insert the screw and turn it counterclockwise first until it engages in the thread Tighten the screw slightly Check the fla...

Page 135: ...ht range Check the headlight setting p 132 800084 10 Turn adjusting screw to adjust the headlight range Guideline For a motorcycle with rider the light dark boundary must be exactly on the lower mark...

Page 136: ...Remove filter box top 100286 10 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never ride the vehicle without an air filter since dust and dirt can...

Page 137: ...flush against the air filter box along the entire sealing sur face If the air filter is not correctly mounted dust and dirt can penetrate into the engine and can cause damage Hook filter box top into...

Page 138: ...temperature 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...

Page 139: ...olant out of the reach of children 100283 10 Condition Engine is cold Stand the motorcycle on its side stand on a horizontal surface Remove the cap of the compensating tank Check antifreeze of coolant...

Page 140: ...not meet specifications Rectify 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 9 73 Checking the...

Page 141: ...each of children 100283 10 Condition Engine is cold Stand the motorcycle on its side stand on a horizontal surface Check the coolant level in the compensating tank The coolant level must be within the...

Page 142: ...Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash a...

Page 143: ...octor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolant out of the rea...

Page 144: ...t the engine and run it until the 5th bar of the temperature indicator lights up Switch off the engine and allow it to cool down After the engine has cooled down check the coolant level in the radiato...

Page 145: ...l of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc Do not use brake fluid Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi...

Page 146: ...ust the play in the throttle cable x p 145 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure...

Page 147: ...cable play 3 5 mm 0 12 0 2 in Tighten counter nut 9 80 Checking the engine oil level Info The engine oil level must be checked when the engine is warm Stand the motorcycle upright on a horizontal sur...

Page 148: ...2 Draining 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...

Page 149: ...clean the oil drain plug with a magnet Mount the oil drain plug with the magnet and seal ring and tighten it Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft 9 83 Removing the oil filter...

Page 150: ...regulations Place a suitable container under the engine 100202 10 Remove screws Remove the oil filter cover with the O ring Pull oil filter out of the oil filter housing Circlip pliers reverse 5101201...

Page 151: ...Cleaning the oil screens x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse i...

Page 152: ...e O rings 100206 10 Remove plug with oil screen and the O rings Completely drain the remaining engine oil Thoroughly clean the parts and sealing area 100207 10 Position oil screen with the O rings Mou...

Page 153: ...1 lbf ft 9 86 Filling up with engine oil x Info Too little engine oil or poor quality engine oil results in premature wear to the engine 100209 10 Remove filler plug with O ring from the clutch cover...

Page 154: ...rt the engine and check that it is oil tight Check the engine oil level p 145 9 87 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the engine 10020...

Page 155: ...ng them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective...

Page 156: ...start Operating error Carry out the start procedure p 49 Fuse 4 blown Change the fuses of individual power consumers p 122 Coupling of fuel hose connection not connected Reconnect coupling of fuel ho...

Page 157: ...flashes Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool x Engine dies during the journey Lack of fuel Refuel p 56 Fuse 1 2 or 4 blown Change the fuses of ind...

Page 158: ...parked Recharge the battery x p 118 Battery is not charged by alternator Check the charging voltage x Check the quiescent current x Combination instrument shows nothing in the display Fuse 1 blown Ch...

Page 159: ...warning lamp MIL flashes briefly 8x Error level condition Accelerator position sensor input signal too low Accelerator position sensor input signal too high Blink code FI of warning lamp MIL 09 FI wa...

Page 160: ...re sensor input signal too low Ambient air pressure sensor input signal too high Blink code FI of warning lamp MIL 15 FI warning lamp MIL flashes 1x long 5x short Error level condition Rollover sensor...

Page 161: ...MIL 37 FI warning lamp MIL flashes 3x long 7x short Error level condition Ignition coil cylinder 1 circuit fault Blink code FI of warning lamp MIL 41 FI warning lamp MIL flashes 4x long 1x short Erro...

Page 162: ...long 4x short Error level condition Secondary air valve short circuit to ground or open circuit Blink code FI of warning lamp MIL 58 FI warning lamp MIL flashes 5x long 8x short Error level condition...

Page 163: ...L 91 FI warning lamp MIL flashes 9x long 1x short Error level condition CAN bus communication error Blink code FI of warning lamp MIL 92 FI warning lamp MIL flashes 9x long 2x short Error level condit...

Page 164: ...icable regulations Info If you clean the motorcycle regularly its value and appearance will be maintained over a long period Avoid direct sunshine on the motorcycle during cleaning Seal the exhaust sy...

Page 165: ...e motorcycle has cooled off oil or grease all moving parts and bearings Clean the chain p 79 Treat bare metal parts except for brake discs and exhaust system with anti corrosion materials Cleaning and...

Page 166: ...clean it with cold water Warm water would enhance the corrosive effects of salt Clean the motorcycle p 162 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with...

Page 167: ...an fill up with fresh fuel when you put the motorcycle back into operation Clean the motorcycle p 162 Change the engine oil and filter clean the oil screens x p 146 Check the antifreeze and coolant le...

Page 168: ...up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 14 2 Putting into operation after storage Take the front from the work stand p 62 Take th...

Page 169: ...0 13 mm 0 0028 0 0051 in Crankshaft bearing 2 roller bearings Conrod bearing Needle bearing Piston pin bearing Bronze bush Pistons Forged light alloy Piston rings 1 L ring 1 tapered compression pisto...

Page 170: ...R 8AI 9 Spark plug electrode gap 0 9 mm 0 035 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid Electric starter automatic decompressor 15 1 Capacity engine oil Engi...

Page 171: ...l filter cover M5 6 Nm 4 4 lbf ft Screw oil pump cover M5 6 Nm 4 4 lbf ft Loctite 243 Plug vacuum connection M6 10 Nm 7 4 lbf ft Loctite 243 Screw in alternator cover M6 10 Nm 7 4 lbf ft Screw alterna...

Page 172: ...rail M6 10 Nm 7 4 lbf ft Loctite 243 Screw timing chain tensioning rail M6 10 Nm 7 4 lbf ft Loctite 243 Screw valve cover M6 10 Nm 7 4 lbf ft Screw water pump cover M6 10 Nm 7 4 lbf ft Screw water pu...

Page 173: ...net M12x1 5 20 Nm 14 8 lbf ft Oil pressure regulator valve plug M12x1 5 20 Nm 14 8 lbf ft Plug oil bore M14x1 5 15 Nm 11 1 lbf ft Loctite 243 Engine case stud M16x1 5 25 Nm 18 4 lbf ft Loctite 243 Rot...

Page 174: ...Front Disc brake with radially screwed four piston brake caliper floating brake disc Rear Disc brake with single piston brake caliper floating Brake discs diameter Front 320 mm 12 6 in Rear 240 mm 9...

Page 175: ...missible rear axle load 200 kg 441 lb Maximum permissible overall weight 350 kg 772 lb Battery YTZ10S Battery voltage 12 V Nominal capacity 8 6 Ah maintenance free Fuse 58011109130 30 A Fuse 750110880...

Page 176: ...M C 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 17 3 Capacity fuel Tot...

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: ...payload 0 5 turn Compression damping low speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full pay...

Page 179: ...TECHNICAL DATA SHOCK ABSORBER 177 Riding sag 70 80 mm 2 76 3 15 in Fitted length 400 mm 15 75 in Shock absorber fluid Shock absorber oil SAE 2 5 50180342S1 p 183...

Page 180: ...eat lock M5 3 Nm 2 2 lbf ft Loctite 222 Screw side cover M5 2 Nm 1 5 lbf ft Screw side stand switch M5 3 Nm 2 2 lbf ft Screw starter cable on starter M5 3 Nm 2 2 lbf ft Spoke nipple rear wheel M5 4 Nm...

Page 181: ...rame M8 30 Nm 22 1 lbf ft Screw exhaust clamp on main silencer M8 25 Nm 18 4 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front footrest bracket M8 25 Nm 18 4 lbf ft Screw fuel tank bottom M8 20...

Page 182: ...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 caliper M10x1 25 45 Nm 33 2 lbf ft Loctite 243 La...

Page 183: ...products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant also in countries with high temperatures Use of low quality antifree...

Page 184: ...e corresponding properties KTM recommends Motorex products Synthetic engine oil Supplier Motorex Motorex KTM Cross Power 4T Engine oil SAE 10W 50 According to JASO T903 MA p 188 SAE p 188 SAE 10W 50 G...

Page 185: ...fluid 15 According to ISO VG 15 Guideline Use only hydraulic fluid that complies with the specified standards see specifications on the container and that possesses the corre sponding properties KTM r...

Page 186: ...SUBSTANCES 184 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91...

Page 187: ...be for road use Guideline KTM recommends Motorex products Supplier Motorex Chain Lube 622 Strong Cleaning and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex product...

Page 188: ...e grease Guideline KTM recommends Motorex products Supplier Motorex Fett 2000 Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Paint cleaner and polish for...

Page 189: ...AUXILIARY SUBSTANCES 187 Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Universal...

Page 190: ...e intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with...

Page 191: ...linings front brake changing 91 94 front brake checking 90 front brake removing 93 rear brake changing 101 rear brake checking 100 Brakes 54 Braking 54 C Chain checking 83 cleaning 79 dirt checking fo...

Page 192: ...button 30 Emergency OFF switch 29 Engine running in 45 Engine characteristic adjusting 124 Engine number 25 Engine oil adding 152 changing 146 draining 146 refilling 151 Engine oil level checking 145...

Page 193: ...sk with headlight installing 127 removing 125 Headlight setting checking 132 Horn button 29 I Ignition lock 30 Indicator lamps 32 K Key number 25 L Light switch 28 Loading the vehicle 46 M Main fuse c...

Page 194: ...stalling 108 removing 107 Refueling fuel 56 Riding 50 starting up 50 S Seat mounting 116 removing 115 Seat release 40 Service plan 59 61 Shift lever 41 Shifting 50 Shock absorber 64 compression dampin...

Page 195: ...engine 167 168 engine tightening torques 169 171 fork 175 shock absorber 176 177 Tire air pressure checking 114 Tire condition checking 111 Transport 9 Troubleshooting 154 156 Tubeless tire system 114...

Page 196: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 11 2009 Photo Mitterbauer 3211518en 3211518en...

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