KTM 690 Supermoto Limited Edition EU 2009 Owner'S Manual Download

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OWNER'S MANUAL

2009

690 Supermoto Limited Edition EU

Art. no. 3211364en

Summary of Contents for 690 Supermoto Limited Edition EU 2009

Page 1: ...OWNER S MANUAL 2009 690 Supermoto Limited Edition EU Art no 3211364en...

Page 2: ......

Page 3: ...for this model at the time of going to print Minor differences due to developments in design cannot be ruled out completely All specifications are non binding KTM Sportmotorcycle AG specifically reser...

Page 4: ...only with the express written permission of the copyright owner ISO 9001 12 100 6061 According to the international quality management standard ISO 9001 KTM uses quality assurance processes that lead...

Page 5: ...lamps 25 Combination instrument display 26 Combination instrument speedometer 27 Setting kilometers or miles 27 Combination instrument time 28 Setting the clock 28 Combination instrument display ODO 2...

Page 6: ...ont brake linings 72 Checking free play of foot brake lever 72 Checking rear brake fluid level 73 Adding rear brake fluid x 74 Checking the rear brake linings 75 Removing the front wheel x 76 Installi...

Page 7: ...x 117 Installing the oil filter x 118 Cleaning the oil screens x 118 Refilling with engine oil x 120 Adding engine oil 121 TROUBLESHOOTING 123 BLINK CODE 126 CLEANING 131 Cleaning motorcycle 131 PROT...

Page 8: ...hnical 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 speci...

Page 9: ...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 10: ...unter 59029019000 During assembly non reusable parts e g self locking screws and nuts seals and seal rings O rings pins lock washers must be replaced by new parts If a thread lock e g Loctite is used...

Page 11: ...d to conflicts with other persons But if you use your motorcycle responsibly you can ensure that such problems and conflicts do not have to occur To protect the future of motorcycle sport make sure th...

Page 12: ...if the appropriate measures are not taken Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken Owner s manual It is important that you read thi...

Page 13: ...11...

Page 14: ...VIEW OF VEHICLE 12 3 1 View of vehicle front left side 600882 10...

Page 15: ...VIEW OF VEHICLE 13 1 Combination instrument 2 Rear mirror 3 Clutch lever 4 Seat 5 Handrail 6 Front brake caliper 7 Left fuel tap 8 Shift lever 9 Engine number 10 Side stand...

Page 16: ...VIEW OF VEHICLE 14 3 2 View of vehicle rear right 600881 10...

Page 17: ...t flasher switch turn signal switch horn 3 Filler cap 4 Emergency OFF switch electric starter button 5 Hand brake lever 6 Chassis number type label 7 Brake caliper rear 8 Passenger footrests 9 Foot br...

Page 18: ...number is stamped on the right of the steering head The type label is on the right of the frame behind the steering head 4 2 Key number 100179 10 The key number can be found on the KEYCODECARD Info Y...

Page 19: ...MBERS 17 4 3 Engine number 500001 01 The engine number is stamped on the left side of the engine under the engine sprocket 4 4 Fork part number 100184 10 The fork part number is stamped on the inner s...

Page 20: ...LOCATION OF SERIAL NUMBERS 18 4 5 Shock absorber part number 100185 10 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side...

Page 21: ...er is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 5 2 Hand brake lever 500018 01 The hand brake lever is fitted on the right side of the handlebar...

Page 22: ...light are switched on High beam on Light switch is turned upwards In this position the high beam and the tail light are switched on 5 4 Headlight flasher switch 500020 11 The headlight flasher switch...

Page 23: ...the central position after use Right turn signal on The turn signal switch is pressed to the right The turn signal switch automatically returns to the central position after use To switch off the tur...

Page 24: ...on 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 can be removed 5 8 Emergency OFF switch...

Page 25: ...lectric starter button in basic position Electric starter button pressed In this position the electric starter is actuated 5 10 Combination instrument 700116 01 The combination instrument is installed...

Page 26: ...aveled 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 5 12 Combinat...

Page 27: ...eed 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 Temperature warning lamp lights up red Coolant has reach...

Page 28: ...ents light up for one second as a function test 700119 01 LEnGth Following the display function test the LEnGth wheel circumference is shown for one sec ond Info 1870 mm corresponds to the circumferen...

Page 29: ...speed is shown in kilometers per hour km h or in miles per hour mph 5 16 Setting kilometers or miles Info If you change the unit the value ODO is retained and converted accordingly Making the setting...

Page 30: ...s active Keep the MODE button pressed until the display mode changes from km h to mph or from mph to km h 5 17 Combination instrument time 700115 01 The time is shown in area of the display Info The t...

Page 31: ...ton pressed simultaneously The time is set 5 19 Combination instrument display ODO 700120 01 In the ODO display mode the total distance traveled is shown in kilometers or miles Info This value is reta...

Page 32: ...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 33: ...F display the fuel warning light switches on 5 23 Combination instrument coolant temperature indicator 700124 01 The temperature display consists of 12 bars The more bars that light up the hotter the...

Page 34: ...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 25 Closing filler cap 500023 01 Put the filler cap back on an...

Page 35: ...e The level cannot be compensated and no fuel can flow out of the fuel tank Fuel tap open The knurled screws are turned counterclockwise as far as possible The level can be compensated and the fuel ca...

Page 36: ...at lock 100108 10 The seat lock is located to the right of the seat You can lock it with the ignition key 5 29 Owner s manual 500031 10 You can find the owner s manual in its protective case on the un...

Page 37: ...he storage compartment under the seat 5 31 Passenger footrests 500036 10 The passenger footrests can be folded in and out Possible states Passenger footrests folded up For operation without a passenge...

Page 38: ...5 32 Shift lever 100110 10 The shift lever is mounted on the left side of the engine 100111 10 The gear positions can be seen in the photograph The neutral or idle position is between the first and s...

Page 39: ...Side stand 500034 10 The side stand is coupled with the safety electric starter system see the riding instruc tions Possible states Side stand folded out The vehicle can be supported on the side stan...

Page 40: ...ted 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 tir...

Page 41: ...ust the basic position of hand brake lever p 69 Adjust the basic position of the foot brake lever Get used to handling the vehicle on a car park before making a longer trip Try also to ride as slowly...

Page 42: ...characteristics at high speed Adapt your speed according to your payload Ride more slowly if your motorcycle is loaded with cases or other baggage Maximum speed with baggage 130 km h 80 8 mph Warning...

Page 43: ...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 distrib...

Page 44: ...the fork legs p 61 Guideline All 1 000 km 621 4 mi Check the chain tension p 63 Clean the chain p 62 Check the tire condition p 82 Check the tire pressure p 84 Check the front brake fluid level p 69 C...

Page 45: ...entilation and do not start or run the engine in a closed space Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic components and safety e...

Page 46: ...ction test of the combination instrument is finished When starting DO NOT open the throttle If you open the throttle during the start ing procedure fuel is not injected by the engine management system...

Page 47: ...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 traffic activi...

Page 48: ...e tires have been run in Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational and with a...

Page 49: ...release the clutch and open the throttle Info You can see the positions of the six forward gears in the figure The neutral or idle position is between the first and second gears First gear is used fo...

Page 50: ...ning Danger of accidents If you brake too hard the wheels can lock Adapt your braking to the traffic situation and the road conditions Warning Danger of accidents Reduced braking due to wet or dirty b...

Page 51: ...Change down to a lower gear appropriate to your road speed On long downhill stretches use the braking effect of the engine Change down one or two gears but do not overstress the engine In this way yo...

Page 52: ...could fall over Brake the motorcycle Shift gear to neutral Switch off the ignition by turning the ignition key to the position Info If the engine is switched off with the emergency OFF switch and the...

Page 53: ...d a health hazard Avoid contact of the fuel with skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas...

Page 54: ...l fuel tank capacity approx 13 5 l 3 57 US gal Super unleaded ROZ 95 RON 95 PON 91 p 152 Close the filler cap p 32 100121 10 Press the SET button for two seconds The fuel level warning lamp switches o...

Page 55: ...orrect fit ting and leaks x Clean check and grease the O ring of the fuel hose connection x Check the wiring harness of the throttle valve body for damage and correct routing x Attachments Check the c...

Page 56: ...vel p 73 Change brake fluid x Check brake lines for damage and leakage Check the free play of the foot brake lever p 72 Check braking Check screws and guide bolts of brake system for tightness x Chass...

Page 57: ...er 1 000 km 621 4 mi K50A every 5 000 km 3 107 mi K100A every 10 000 km 6 214 mi J1A annually J2A every 2 years 8 2 Important maintenance work to be carried out by an authorized KTM workshop as additi...

Page 58: ...SERVICE SCHEDULE 56 J2A every 2 years...

Page 59: ...bar 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 fr...

Page 60: ...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 61: ...d should always 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 particularl...

Page 62: ...g 9 7 Adjusting the rebound damping of the shock absorber Danger Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere...

Page 63: ...ks Info Turn clockwise to increase rebound damping turn counterclockwise to reduce rebound damping 9 8 Bleeding the fork legs Lean the motorcycle on the side stand 100124 10 Remove bleeder screws brie...

Page 64: ...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 o...

Page 65: ...g Danger of accidents Danger caused by incorrect chain tension If the chain is over tensioned the components of the secondary power train chain engine sprocket rear sprocket bearings in transmission a...

Page 66: ...st the chain tension p 64 9 12 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain is over tensioned the components of the secondary power tra...

Page 67: ...e 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 68: ...r sprocket engine sprocket are worn Replace rear sprocket engine sprocket Info The engine sprocket rear sprocket and chain should always be replaced together For safety reasons the chain has no chain...

Page 69: ...even so you should repeat this measurement at differ ent chain positions Maximum distance at the longest chain section 272 mm 10 71 in If distance is greater than the specified measurement Have the ch...

Page 70: ...ont and rear 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 F...

Page 71: ...e front brake fluid level Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linin...

Page 72: ...tem or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on conta...

Page 73: ...for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid is corrosive and will damage painted surfaces Use only clean brake fluid from a sealed container Move the brake f...

Page 74: ...and the brake discs are rendered unserviceable Check the brake linings regularly 601000 10 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less...

Page 75: ...TM workshop Attach spring 9 21 Checking rear brake fluid level Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicates a leakage in the...

Page 76: ...inings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with s...

Page 77: ...Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 100176 10 Stand the vehicle upright Remove the screw cap with the membr...

Page 78: ...ckness 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 wear or tearing Change the rear brake li...

Page 79: ...f the fork 9 25 Installing the front wheel x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean...

Page 80: ...n Tighten screws Guideline Screw front brake caliper M10x1 25 45 Nm 33 2 lbf ft Loctite 243 Remove the fixation of the hand brake lever 601012 10 Take the front from the work stand p 57 Pull the front...

Page 81: ...ke caliper support to the side Warning Danger of accidents Reduced braking efficiency caused by damaged brake discs Always lay the wheel down in such a way that the brake disc is not damaged Take the...

Page 82: ...swingarm Install the rubber damper and rear sprocket carrier in the rear wheel Stand the rear wheel in the swingarm and mount the brake caliper on the brake disc 601004 10 Push the brake caliper suppo...

Page 83: ...nfo The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers They eventually wear out during operation If the rubber dampers are not changed in time the rear sproc...

Page 84: ...e rear wheel x p 79 9 29 Checking the tire condition Warning Danger of accidents Uncontrollable handling characteristic caused by a flat tire For your own safety have damaged tires changed immediately...

Page 85: ...fo The type condition and air pressure of the tires all have a major impact on the handling of the motorcycle Worn tires have a negative effect on riding behavior especially on wet surfaces 400602 10...

Page 86: ...after five years If a tire is more than five years old Change the tires 9 30 Checking the tire pressure Info Low tire pressure leads to abnormal wear and overheating of the tire Correct tire pressure...

Page 87: ...more loose spokes If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle 400694 01 Briefly strike each spoke with a screwdriv...

Page 88: ...e 9 33 Mounting the seat 400155 01 Suspend the seat on the screw press the rear downwards and at the same time push it forwards The two projections must be inserted into the frame Push the locking pin...

Page 89: ...t need to be disconnected 100174 10 Lay a cloth over the subframe and straighten the steering Carefully raise the fuel tank and move it backwards Place the fuel tank on the vehicle so that the left sp...

Page 90: ...e compensating tank and the spoiler 100175 10 Carefully move the fuel tank forwards and lower it Mount and tighten the screw with the rubber bushing and bearing sleeve Check fuel tank for tight fittin...

Page 91: ...e with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Remove the seat p 86 Reinstall the fuel tank p 87 100169 10 Disconnect the...

Page 92: ...ization Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep the battery away from sparks or open fire Charg...

Page 93: ...e life If the charging current charging voltage and charging time are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting...

Page 94: ...he battery with a maximum of 10 of the capacity specified on the bat tery housing Switch off the charger after charging Disconnect the battery Guideline The charge current charge voltage and charge ti...

Page 95: ...otective cover Remove a defective main fuse with a needle nose plier Install a new main fuse Fuse 58011109130 p 142 Info A reserve fuse is located in the starter relay Replace the protective cover Pos...

Page 96: ...ttle valve control unit Fuse 4 10A fuel pump Fuse 5 10A radiator fan Fuse 6 10A horn brake light turn signal alarm system optional Fuse 7 15A high beam low beam parking light tail light license plate...

Page 97: ...pair fuses Use spare fuses with the correct rating only Fuse 75011088010 p 142 Fuse 75011088015 p 142 Tip Replace the spare fuse in the fuse box so that it is available if needed Check that the power...

Page 98: ...out of the headlight housing Pull the plug in connector off the headlight Place the headlight mask to one side 9 42 Refitting the headlight mask with the headlight 100156 11 Connect the plug in connec...

Page 99: ...lbf ft Check lighting function 9 43 Changing the headlight bulb Note Damage to reflector Reduced luminance Grease on the bulb will evaporate due to the heat and be deposited on the reflector Clean th...

Page 100: ...headlight bulb so that the bayonet lugs latch into the slots Position the bulb holder and turn it clockwise all the way Replace the rubber cap Refit the headlight mask with the headlight p 96 9 44 Cha...

Page 101: ...rate due to the heat and be deposited on the reflector Clean the bulb and keep it free of grease before mounting 100160 10 Remove the screw on the rear of the turn signal housing Carefully remove diff...

Page 102: ...make a mark as high as the center of the low beam headlight Make another mark at a distance of under the first mark Guideline Distance 5 cm 2 in Stand the motorcycle at a distance of in front of the...

Page 103: ...the light range If you have a payload you may have to correct the headlight range 9 48 Cooling system 100166 10 The water pump in the engine forces the coolant to flow The pressure in the cooling sys...

Page 104: ...hoses or other cooling system components when the engine is hot Allow the engine and cool ing system to cool down In case of burns rinse immediately with lukewarm water Warning Danger of poisoning Coo...

Page 105: ...ifreeze 25 45 C 13 49 F If the coolant antifreeze does not meet specifications Correct the coolant antifreeze Check the coolant level in the compensating tank The coolant level must be between MIN and...

Page 106: ...vel 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 Alternative 1 Coolant p 150 Al...

Page 107: ...es and clothing If fuel gets into your eyes rinse immediately with water and con tact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immedia...

Page 108: ...to use p 150 If you had to add more coolant than the specified amount 0 50 l 0 53 qt Fill bleed the cooling system x p 107 Mount the radiator cap Position the fuel tank p 88 Mount the seat p 86 9 51...

Page 109: ...10 Stand the motorcycle upright Place a suitable container under the engine Remove screw Remove the radiator cap Completely drain the coolant Mount screw with a new seal ring and tighten it Guideline...

Page 110: ...lant until it emerges without bubbles at the vent hole and then mount and tighten the bleeder screw immediately Alternative 1 Coolant p 150 Alternative 2 Coolant mixed ready to use p 150 Fill the radi...

Page 111: ...is cool check the coolant level in the radiator and if necessary add coolant Remove the cap of the compensating tank and add coolant until the coolant level is up to the MAX mark Mount the cap of the...

Page 112: ...parts of the vehicle Guideline Minimum clearance 5 mm 0 2 in 9 54 Checking the basic position of the shift lever 0 0 0 A A 400692 10 Sit on the vehicle in the riding position and determine the distanc...

Page 113: ...lean gear teeth of the shift lever and shift shaft Mount the shift lever on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever may...

Page 114: ...der top level of container 4 mm 0 16 in If the level of the coolant does not meet specifications Correct the fluid level of the hydraulic clutch Hydraulic fluid 15 p 152 Position the cover with the me...

Page 115: ...le Move the handlebar to and fro over the entire steer ing range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable x p 113 9 58 Adjusting the play in the t...

Page 116: ...as it will go If the handlebar instruments touch the fuel tank Correct the handlebar angle Info The distance between the handlebar support and the handlebar clamp must be the same at the front and re...

Page 117: ...t at the specified level Add the engine oil p 121 9 61 Changing the engine oil and filter cleaning the oil screens x 601022 10 Drain the engine oil x p 115 Remove the oil filter x p 117 Clean the oil...

Page 118: ...he engine oil only when the engine is warm Stand the motorcycle on its side stand on a horizontal surface 700106 01 Place a suitable container under the engine Remove the oil drain plug with the magne...

Page 119: ...of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as s...

Page 120: ...a 9 64 Installing the oil filter x 700105 01 Insert oil filters and Oil the O rings of the oil filter covers Mount oil filter covers and Mount and tighten the screws Guideline Screw oil filter cover M...

Page 121: ...ers fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Place a suitable container under the engine 700109 01 Remove plug with oil screen and the O rings 700110...

Page 122: ...ring Guideline Plug oil screen M20x1 5 15 Nm 11 1 lbf ft 700112 01 Position oil screen with the O rings Mount and tighten plug with the O ring Guideline Plug oil screen M20x1 5 15 Nm 11 1 lbf ft 9 66...

Page 123: ...tighten the oil filler plug with O ring Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine always make sure there is suffici...

Page 124: ...ine oil do not mix different types of engine oil If appropriate change the engine oil Install and tighten the oil filler plug with O ring Danger Danger of poisoning Exhaust gases are poisonous and can...

Page 125: ...nection Engine turns only if the clutch lever is drawn The vehicle is in gear Shift gear to neutral The vehicle is in gear and the side stand is folded out Shift gear to neutral Defect in safety start...

Page 126: ...e radiator hose changed Thermostat defective Have thermostat checked Fuse 5 blown Change the fuses of individual power consumers p 93 Defect in radiator fan system Have the radiator fan system checked...

Page 127: ...Fuse 2 blown Change the fuses of individual power consumers p 93 Set the clock p 28 Battery discharged Ignition not switched off when vehicle was parked Recharge the battery x p 90 Battery is not char...

Page 128: ...on Manifold absolute pressure sensor cylinder 1 input signal too low Manifold absolute pressure sensor cylinder 1 input signal too high Blink code FI of warning lamp MIL 13 FI warning lamp MIL flashes...

Page 129: ...Lambda sensor cylinder 1 sensor 1 circuit fault Blink code FI of warning lamp MIL 33 FI warning lamp MIL flashes 3x long 3x short Error level condition Injector cylinder 1 circuit fault Blink code FI...

Page 130: ...circuit to ground or open circuit Blink code FI of warning lamp MIL 24 FI warning lamp MIL flashes 2x long 4x short Error level condition System voltage circuit fault Blink code FI of warning lamp MI...

Page 131: ...EPT throttle motor drive circuit fault Blink code FI of warning lamp MIL 58 FI warning lamp MIL flashes 5x long 8x short Error level condition EFI control unit and EPT control unit checking the contro...

Page 132: ...o high Blink code FI of warning lamp MIL 91 FI warning lamp MIL flashes 9x long 1x short Error level condition CAN bus communication error Blink code FI of warning lamp MIL 60 FI warning lamp MIL flas...

Page 133: ...le regulations Info If you clean the motorcycle regularly its value and appearance are maintained over a long period Avoid direct sunshine on the motorcycle during cleaning Before you clean the motocy...

Page 134: ...covers on the handlebar instruments to allow water to evaporate After the motorcycle has cooled off oil or grease all moving parts and bearings Clean the chain p 62 Treat bare metal parts except for b...

Page 135: ...clean it with cold water Warm water would enhance the corrosive effects of salt Clean the motorcycle p 131 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with...

Page 136: ...ou can fill up with fresh fuel when you put the motorcycle back into operation Clean the motorcycle p 131 Change the engine oil and filter clean the oil screens x p 115 Check the antifreeze and coolan...

Page 137: ...warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 14 2 Putting into operation after storage Take the front from the work stand p 57 Tak...

Page 138: ...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 139: ...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 Engin...

Page 140: ...il filter cover M5 6 Nm 4 4 lbf ft Screw oil pump cover M5 6 Nm 4 4 lbf ft Loctite 243 Plug vacuum connection M6 10 Nm 7 4 lbf ft Loctite 243 Screw Autodecompression M6 3 4 Nm 2 2 3 lbf ft Loctite 243...

Page 141: ...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 142: ...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 143: ...m 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 144: ...Maximum permissible rear axle load 200 kg 441 lb Maximum permissible overall weight 350 kg 772 lb Battery YTZ10S Battery voltage 12 V Nominal capacity 8 6 Ah maintenance free Fuse 58011109130 30 A Fus...

Page 145: ...17 M C 58H TT Bridgestone BT090F 160 60 R 17 M C 69H TT Bridgestone BT090R Pro Additional information is available in the Service section under http www ktm com 17 2 Capacity fuel Total fuel tank capa...

Page 146: ...t 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Spring length with preload spacer s 430 mm 16 93 in Spring rate Soft 4 8 N mm 27 4 lb in Medium standard 5 2 N mm 29 7 lb in Hard...

Page 147: ...port 15 clicks Full payload 15 clicks Spring preload 10 mm 0 39 in Spring rate Weight of rider 65 75 kg 143 165 lb 60 N mm 343 lb in Weight of rider 75 85 kg 165 187 lb 65 N mm 371 lb in Weight of rid...

Page 148: ...astic clamp of brake line on fork leg M5 2 Nm 1 5 lbf ft Screw pressure regulator M5 4 Nm 3 lbf ft Screw seat lock M5 3 Nm 2 2 lbf ft Loctite 222 Screw side cover M5 2 Nm 1 5 lbf ft Screw starter cabl...

Page 149: ...10 3 lbf ft Loctite 243 Screw side stand bracket M6 10 Nm 7 4 lbf ft Loctite 243 Screw SLS valve M6 6 Nm 4 4 lbf ft Screw voltage regulator rectifier M6 8 Nm 5 9 lbf ft Nut manifold on cylinder head M...

Page 150: ...upper subframe M8 35 Nm 25 8 lbf ft Loctite 243 Engine carrying screw M10 45 Nm 33 2 lbf ft Loctite 243 Remaining nuts chassis M10 50 Nm 36 9 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Scr...

Page 151: ...14x1 5 100 Nm 73 8 lbf ft Nut swingarm pivot M16x1 5 100 Nm 73 8 lbf ft Screw steering head M20x1 5 12 Nm 8 9 lbf ft Adjusting ring of swingarm bearing M24x1 5 25 Nm 18 4 lbf ft Screw front wheel spin...

Page 152: ...torex 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 ant...

Page 153: ...ss the 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 155 SAE p 155 SAE 10W...

Page 154: ...TM recommends Motorex products Supplier Motorex Racing Fork Oil Hydraulic fluid 15 According to ISO VG 15 Guideline Use only hydraulic fluid that complies with the specified standards see specificatio...

Page 155: ...be for road use Guideline KTM recommends Motorex products Supplier Motorex Chain Lube 622 Strong Cleaning and polishing materials for metal rubber and plastic Guideline KTM recommends Motorex products...

Page 156: ...ier Motorex Moto Polish Long life grease Guideline KTM recommends Motorex products Supplier Motorex Fett 2000 Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 9...

Page 157: ...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 158: ...ecking 75 Brakes 48 Braking 48 C Chain cleaning 62 dirt checking for 62 wear checking 67 Chain tension adjusting 64 checking 63 Chassis number 16 Cleaning 131 132 Clutch checking correcting fluid leve...

Page 159: ...ging 115 draining 115 refilling 120 Engine oil level checking 114 Environment 9 F Filler cap closing 32 opening 32 Filling up fuel 51 Foot brake lever 37 free travel checking 72 Fork 59 fork legs blee...

Page 160: ...ng the vehicle 40 M Main fuse changing 92 Maintenance 7 Motorcycle cleaning 131 jacking up front 57 jacking up rear 58 taking front from work stand 57 taking rear from work stand 58 O Oil filter chang...

Page 161: ...g 110 Shifting 45 Shock absorber 59 rebound damping adjusting 60 Shock absorber part number 18 Side stand 37 Spare parts 8 Spoke tension checking 85 Starting 43 Steering lock 22 Stopping 49 Storage 13...

Page 162: ...INDEX 160 U Use definition 7 V View of vehicle front left 12 rear right 14 W Warranty 7 Work rules 8...

Page 163: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 04 2009 Photo Mitterbauer 3211364en 3211364en...

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