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KTM 990 Adventure 2009, Owner'S Manual

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KTM 990 Adventure 2009 Owner'S Manual Download Page 142

MAINTENANCE WORK ON CHASSIS AND ENGINE

140

9.68

Cooling system

100608-10

The water pump

in the engine forces the coolant to flow.

The pressure in the cooling system resulting from heat is regulated by a valve in the radia-
tor cap. This permits the specified coolant temperature without causing any malfunctions.

125 °C (257 °F)

0

0

2

2

0

0

3

3

400619-10

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 cooling effect. Dirty cooling fins also reduce the cooling
effect.
The heat expansion causes the surplus coolant to flow into the compensating tank

. When

the temperature falls, this surplus coolant is sucked back into the cooling system.

Summary of Contents for 990 Adventure 2009

Page 1: ...OWNER S MANUAL 2009 990 Adventure EU 990 Adventure AUS UK 990 Adventure R EU 990 Adventure R AUS UK 990 Adventure R FR ART NO 3211362en...

Page 2: ......

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

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: ...on instrument display 26 Combination instrument speedometer 27 Setting kilometers or miles 27 Combination instrument time 28 Setting the clock 29 Combination instrument display ODO 29 Combination inst...

Page 6: ...absorber 72 Adjusting the low speed compression damping of the shock absorber 72 Adjusting the high speed compression damping of the shock absorber 74 Adjusting the rebound damping of the shock absorb...

Page 7: ...Activating deactivating the ignition key 132 Removing the storage compartment and hanging it to one side x 135 Installing the storage compartment x 136 Removing the left fuel tank x 137 Installing the...

Page 8: ...Capacity engine oil 181 Capacity coolant 181 TECHNICAL DATA ENGINE TIGHTENING TORQUES 182 TECHNICAL DATA CHASSIS 185 Lighting equipment 187 Tires 188 Capacity fuel 188 TECHNICAL DATA FORK 189 990 Adve...

Page 9: ...nical understanding In the interest of your own safety have these jobs performed in an authorized KTM workshop There your motorcycle will be serviced opti mally by specially trained experts using the...

Page 10: ...y or 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...

Page 11: ...ng 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...

Page 12: ...with other persons Responsible behavior in handling the motorcycle can help to avoid such problems and con flicts To protect the future of motorcycle sport make sure that you use your motorcycle legal...

Page 13: ...ge 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 Be sure to read this owner s ma...

Page 14: ...VIEW OF VEHICLE 12 3 1 View of vehicle front left side vehicle differs slightly from photo 100540 10...

Page 15: ...IEW OF VEHICLE 13 1 Clutch lever 2 Seat 3 Seat lock 4 Luggage rack plate 5 Handrail 6 Front brake caliper 7 Underride guard 8 Side stand 9 Shift lever 10 Footrest 11 Center stand 12 Passenger footrest...

Page 16: ...VIEW OF VEHICLE 14 3 2 View of vehicle rear right side vehicle differs slightly from photo 100541 10...

Page 17: ...switch horn button headlight flasher switch 3 Hazard warning flasher switch 4 Accessories socket 5 Emergency OFF switch electric starter button 6 Hand brake lever 7 Filler cap 8 Rear brake caliper 9 F...

Page 18: ...umber 100542 10 The chassis number is stamped on the right side of the steering head The chassis number is also found on the type label 4 2 Type label 100543 10 The type label is located on the right...

Page 19: ...a spare key Keep the KEYCODECARD in a safe place Use the orange programming key to activate and deactivate the black ignition key Keep the orange programming key in a safe place it must only be used f...

Page 20: ...S 18 4 5 Fork part number 100545 10 The fork part number is stamped on the inner side of the fork stub 4 6 Shock absorber part number 100546 10 The shock absorber part number is stamped on the upper p...

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 100506 10 The hand brake lever is fitted on the right side of the handlebar...

Page 22: ...ight are switched on High beam on The light switch is turned upwards In this position the high beam and tail light are switched on 5 4 Headlight flasher switch 100508 10 The headlight flasher switch i...

Page 23: ...to the central position after use Turn signal right 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 t...

Page 24: ...n circuit is closed and the engine can be started Steering locked In this position the ignition circuit is interrupted and the steering locked The black ignition key can be removed 5 8 Immobilizer 100...

Page 25: ...The emergency OFF switch is fitted on the right side of the handlebar Possible states Emergency OFF switch off In this position the ignition circuit is inter rupted a running engine stops and the engi...

Page 26: ...5 12 Combination instrument function buttons 100492 10 You can change the display mode with the MODE button Possible display modes are the distance traveled ODO trip master 1 TRIP 1 trip mas ter 2 TRI...

Page 27: ...tate of the motorcy cle Possible states The turn signal indicator lamp flashes green simultaneously with the turn signals The turn signal is switched on The idle speed indicator lamp lights up green T...

Page 28: ...cator lamp lights up or flashes red Status or error message for immobilizer alarm system The battery warning lamp lights up red The voltage in vehicle system is too low The ABS warning lamp lights up...

Page 29: ...ront wheel with a series production tire The display then changes to the last selected mode 5 16 Combination instrument speedometer 100503 10 The speed is shown in kilometers per hour km h or in miles...

Page 30: ...Press the MODE button repeatedly until the ODO mode is active Keep the MODE button pressed until the display mode changes from km h to mph or from mph to km h 5 18 Combination instrument time 100502 1...

Page 31: ...e SET button pressed simultaneously The time display begins to flash Press the MODE button to set the hour Press the SET button to set the minute Keep the MODE button and the SET button pressed simult...

Page 32: ...n 700121 01 Switch on the ignition by turning the black ignition key to the position Press the MODE button repeatedly until the TRIP 1 mode is active Keep the SET button pressed The TRIP 1 display is...

Page 33: ...s active Keep the SET button pressed The TRIP 2 display is set to 0 0 5 23 Combination instrument TRIP F display 100499 10 If the fuel level drops to the reserve mark the display automatically changes...

Page 34: ...5 25 Setting the temperature unit of measure Condition The motorcycle is standing 100500 11 Switch on the ignition by turning the black ignition key to the position Press the MODE button repeatedly un...

Page 35: ...isplay when the ambient temperature rises above the specified value again Temperature 4 C 39 F 5 27 Combination instrument coolant temperature indicator 400617 01 The temperature display consists of 1...

Page 36: ...er switch is found to the left of the combination instrument The hazard warning flasher is used to signal an emergency situation and to warn other road users Info Activate deactivate the hazard warnin...

Page 37: ...o filler necks The fuel tanks are connected to each other with a fuel line that equalizes the fuel level The two filler caps are equipped with a ventilation system 5 31 Closing the filler caps 100515...

Page 38: ...and locks and unlocks the storage compartment Possible states Storage compartment locked Storage compartment unlocked Seat unlocked The seat lock can be locked with the ignition key 5 33 Unlocking the...

Page 39: ...Turn the ignition key to position Remove the ignition key 5 35 Opening the storage compartment 100520 10 Unlock the storage compartment p 36 Press button toward the seat and raise the cover at the sa...

Page 40: ...y engages Info The storage compartment can be opened again as long as it has not been locked using the seat lock Lock the storage compartment p 37 5 37 Handrails 100522 10 The handrails are used for m...

Page 41: ...ation provided by the luggage manufacturer 5 39 Fuel taps 100524 10 There is a fuel tap on every fuel tank Info The fuel taps must be open during operation The fuel taps are only closed when dismantli...

Page 42: ...ot brake pedal 100525 10 Foot brake pedal is located in front of the right footrest The rear brake is activated using the foot brake pedal 5 41 Shift lever 100526 10 Shift lever is mounted on the left...

Page 43: ...ond gears 5 42 Side stand 100528 10 Side stand is coupled with the safety start system see the riding instructions Possible states Side stand folded out The vehicle can be leaned on the side stand The...

Page 44: ...center stand in addition to a side stand 5 44 Passenger footrests 100530 10 The passenger footrests can be folded up and down Possible states Passenger footrests folded up For operation without a pas...

Page 45: ...CONTROLS 43 5 45 Tool set 100531 10 The tool set is located in the storage compartment under the seat The extension can be mounted on several of the wrenches in the tool set...

Page 46: ...eels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling characteristics due to non approved and or no...

Page 47: ...Adjust the free travel of the handbrake lever p 88 Adjust the basic position of the footbrake lever x Get used to handling the motorcycle on a suitable piece of land before making a longer trip Try a...

Page 48: ...ing 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 luggage 130 km h 80 8 mph Warn...

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

Page 50: ...m 621 4 mi Check the chain tension p 81 Clean the chain p 80 Check the tire condition p 106 Check the tire air pressure p 107 Check the brake fluid level of the front brake p 89 Check the rear brake f...

Page 51: ...tart or run the engine in a closed space without an effective exhaust extraction system Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic...

Page 52: ...ctric starter button Info Do not press the electric starter button until the function test of the combination instrument is finished When starting DO NOT open the throttle If you open the throttle dur...

Page 53: ...tch lever slowly and simultaneously open the throttle carefully 7 4 Shifting riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control Avoid abrupt load al...

Page 54: ...er as early as possible Warning Danger of accidents Reduced road grip with cold tires On every journey take the first miles carefully at moderate speed until the tires reach operating temperature and...

Page 55: ...of the engine Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear Note Engine failure Overheating of engine If the coolant temperatur...

Page 56: ...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 and close the throttle at the same...

Page 57: ...drag permanently The rear brake can fail due to overheating Take your foot off the foot brake pedal if you do not want to brake Warning Danger of accidents Longer stopping distance due to higher overa...

Page 58: ...ry surface Warning Danger of accidents Road grip is reduced when braking with the motorcycle at an angle or on a laterally inclined surface Braking should be completed before you enter into a bend Bra...

Page 59: ...the machine is driven Do not touch hot components such as exhaust system radiator engine shock absorber and brakes Allow these components to cool down before starting work on them Note Danger of damag...

Page 60: ...ition Info If you switch off the engine with the emergency OFF switch but the ignition remains switched on at the ignition lock power continues to flow to most power consumers and the battery is soon...

Page 61: ...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 im...

Page 62: ...5 3 US gal Super unleaded ROZ 95 RON 95 PON 91 p 201 Info If the right fuel tank is filled to the filler neck fuel may flow out if the vehicle is resting on the side stand and the fuel heats up Close...

Page 63: ...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 64: ...jet for clutch lubrication x Fuel injection Read out the fault memory using the KTM diagnostics tool x Perform a status query with the KTM diagnostics tool for the neutral gear clutch 2nd 3rd gear an...

Page 65: ...heck that the electrical equipment is functioning properly Check the screws and nuts for tightness x Brakes Read out the ABS fault memory using the KTM diagnostics tool 990 Adventure x Check the front...

Page 66: ...the tire condition p 106 Check the tire air pressure p 107 Check the chain wear p 85 Check the rear sprocket engine sprocket chain sliding guard to ensure that they are tight x Check the rear sprocke...

Page 67: ...vice x Perform a shock absorber service x Clean and grease the steering head bearing and sealing elements x Clean the battery poles and treat with contact grease x Change the coolant x K150N after 15...

Page 68: ...e while it is resting on the center stand The center stand or frame could be damaged and the motorcycle could fall over Pull the motorcycle up onto the center stand using the handrail and not the hand...

Page 69: ...e steering and move the vehicle forward with both hands on the handlebar As the vehicle moves off of the center stand activate the front brake to prevent the vehicle from rolling Check that the center...

Page 70: ...e click Finally check that the seat is correctly mounted 9 5 Fork shock absorber 100532 10 The fork and the shock absorber offer many options of adapting the suspension to your rid ing style and the p...

Page 71: ...l they stop Info The adjusting screws are located at the bottom end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise by the number of clicks corresponding to the...

Page 72: ...rebound damping determines the fork rebound behavior 100534 10 Turn adjusting screws clockwise until they stop Info The adjusting screws are located at the top end of the fork legs Make the same adjus...

Page 73: ...turn counterclockwise to reduce damping 9 8 Adjusting the spring preload of the fork 100535 10 Turn the adjusting screws counterclockwise until they stop Info Make the same adjustment on both fork le...

Page 74: ...k absorber The shock absorber can regulate compression damping separately in the low and high speed ranges Dual Compression Control The terms low speed and high speed refer to the movement of the shoc...

Page 75: ...s far as the last perceptible click Info Do not loosen nut Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline 990 Adventure Compression damping low s...

Page 76: ...parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be pleased to help Info The high speed setting ca...

Page 77: ...ns Standard 1 5 turns Sport 1 turn Full payload 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping 9 12 Adjusting the rebound damping of the shock absorb...

Page 78: ...licks corresponding to the shock absorber type Guideline 990 Adventure Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks 990 Adventure R Rebound damping Comfo...

Page 79: ...n provided Your authorized KTM workshop will be pleased to help 100549 10 Turn handweel counterclockwise as far as it will go Turn it clockwise by the number of turns corresponding to the shock absorb...

Page 80: ...uce the spring preload 9 14 Bleeding the fork legs Jack up the vehicle on the center stand p 66 100536 10 Remove bleeder screws briefly Any excess pressure escapes from the interior of the fork Mount...

Page 81: ...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 when necessary Clean and oil the du...

Page 82: ...of oil and grease and clean them with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should...

Page 83: ...he other hand if the chain is loose it may jump off the engine sprocket or the rear sprocket causing the rear wheel to lock or damage the engine Check for correct chain tension and adjust if necessary...

Page 84: ...procket rear sprocket bearings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain may snap or the countershaft of the transmission can break...

Page 85: ...eft and right chain adjuster are in the same position in relation to reference marks The rear wheel is then correctly aligned Info The upper chain section must be taut Chain wear is not always even so...

Page 86: ...ck the rear sprocket engine sprocket for wear If the rear sprocket engine sprocket are worn Change the rear sprocket engine sprocket Info The engine sprocket rear sprocket and chain should always be c...

Page 87: ...easure distance of 18 chain links in the upper chain section Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance at the longest chai...

Page 88: ...a safety system that prevents locking of the wheels when traveling straight ahead without the action of lateral forces ABS works with two mutually independent brake circuits front and rear brake Unde...

Page 89: ...rake disc s without delay Your authorized KTM workshop will be pleased to help 400618 10 Check the thickness of the front and rear brake discs in several places to ensure that it conforms to measureme...

Page 90: ...o overheating Adjust free travel on hand brake lever according to specifications 100555 10 Push the hand brake to the handlebar and check the free travel Free travel of hand brake lever 3 mm 0 12 in I...

Page 91: ...any adjustments while riding 9 26 Checking the brake fluid level of the front brake Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indic...

Page 92: ...or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be pleased to help Warning Skin irritation Brake fluid can cause skin irritation on conta...

Page 93: ...lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 100558 10 Move the brake...

Page 94: ...nd the brake discs are rendered unserviceable Check the brake linings regularly 100559 10 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less...

Page 95: ...l does not meet specifications Adjust the basic position of the footbrake lever x 9 30 Checking the rear brake fluid level Warning Danger of accidents Failure of the brake system If the brake fluid le...

Page 96: ...ake linings Check the brake system and do not continue riding Your authorized KTM workshop will be pleased to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contac...

Page 97: ...in applicable regulations Info Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between...

Page 98: ...s Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be pleased to help Note Danger of accident...

Page 99: ...gs x Check the brake linings for damage and cracking If there is wear or tearing Change the rear brake linings x 9 33 Removing the front wheel x Jack up the vehicle on the center stand p 66 Load the v...

Page 100: ...n the screw to push the wheel spindle out of the fork stub Warning Danger of accidents Reduced braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs...

Page 101: ...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 when necessary 100567 11 Clean and...

Page 102: ...w Guideline Screw front wheel spindle M25x1 5 45 Nm 33 2 lbf ft Raise the vehicle off of the center stand p 67 Pull the front wheel brake and push down hard on the fork several times to align the fork...

Page 103: ...ving the rear wheel x Jack up the vehicle on the center stand p 66 100634 10 Press the brake caliper by hand on to the brake disc in order to press back the brake pistons 100635 10 990 Adventure Remov...

Page 104: ...possible Take the chain off of the rear sprocket and place it on chain sprocket guard Warning Danger of accidents Reduced braking due to damaged brake discs Always lay the wheel down in such a way th...

Page 105: ...n operating the rear brake After installing the rear wheel always operate the footbrake until the pressure point is reached Check the rear hub rubber dampers x p 105 100571 10 Clean and grease shaft s...

Page 106: ...e adjust ing screws and tighten nut Guideline In order for the rear wheel to be correctly aligned the markings on the left and right chain adjusters must be in the same position relative to the refere...

Page 107: ...he rubber dampers of the rear hub for damage and wear If the rubber dampers of the rear hub are damaged or worn Change all rubber dampers in the rear hub 100573 10 Lay the read wheel on a workbench wi...

Page 108: ...g characteristics 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 accidents Reduced ro...

Page 109: ...the age of the tires Info The tire s date of the manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking The first two digits refer to the week of...

Page 110: ...e does not meet specifications Correct the tire pressure Mount the dust cap 9 40 Checking spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that the spo...

Page 111: ...ter If spokes of the same length and diameter vibrate with a different tone this is an indication that the spoke tensions differ You should hear a high note If the spoke tension differs Correct the sp...

Page 112: ...Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases...

Page 113: ...of the battery Disconnect the positive plus cable of the battery Take the battery out of the battery compartment with battery tray Info Never operate the motorcycle with a discharged battery or witho...

Page 114: ...e battery into battery tray Slide the battery with the battery tray into the battery compartment Connect plus cable Connect minus cable 100579 11 Hook cover into the battery compartment at the bottom...

Page 115: ...inse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Warning Environmental hazard Battery parts and acid are harmful to th...

Page 116: ...ed from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become over discharged and sulfate destroyin...

Page 117: ...arger 58429074000 You can also use the battery charger to test rest potential and start potential of the bat tery and to test the generator With this device you cannot overcharge the battery Switch of...

Page 118: ...oving the right underride guard 100581 10 Remove screws Remove the right underride guard 9 47 Installing the right underride guard 100581 11 Position right underride guard Mount and tighten screws Gui...

Page 119: ...se of incorrect fuses Use only fuses with the prescribed amperage Never by pass or repair fuses Info The main fuse is located in the starter relay under the right underride guard Switch off all power...

Page 120: ...e the faulty main fuse Info A defective fuse can be identified by the burned out fuse wire A reserve fuse is located in the starter relay The main fuse protects all power consumers of the vehicle Inst...

Page 121: ...hydraulic unit of the ABS The third fuse which protects the ABS control unit is located in the fuse box Switch off all power consumers and the engine Remove the right underride guard p 116 100585 10 C...

Page 122: ...cover Tip Place the spare fuse in the storage compartment so that it is available if needed Install the right underride guard p 116 9 50 Changing the fuses in the fuse box Warning Fire hazard The ele...

Page 123: ...king light license plate lamp Fuse HORN BRAKE LIGHT 10A horn brake light hazard warning flasher Fuse FAN 10A radiator fan Fuse POWER RELAY 10A ignition EFI control unit Fuse ACC1 CLOCK 10A combination...

Page 124: ...e ABS Tip Replace the spare fuse in the fuse box so that it is available if needed 100637 10 990 Adventure R Use spare fuses with the correct rating only Fuse 58011109110 p 186 Fuse 58011109115 p 186...

Page 125: ...left and right sides 100589 10 Remove screws Carefully swing out the side cover at the top and disconnect the plug in connectors of the turn signal cables Pull off the overflow hose of the fuel tank a...

Page 126: ...he turn signal cables and swing the side cover up toward the vehicle Mount and tighten screws with the washers Guideline Remaining chassis nuts M6 15 Nm 11 1 lbf ft Check the function of turn signal 9...

Page 127: ...dlight mask with the headlight 100591 10 Connect plug in connector Check the lighting function Position the headlight mask Install the front side cover p 123 Check the headlamp setting p 131 9 55 Chan...

Page 128: ...he headlight and attach the spring bar High beam H3 socket PK22s p 187 Info The bulb must be correctly seated at projections Connect the plug in connector and mount the rubber cap Install the headligh...

Page 129: ...tach the spring bar Low beam H7 socket PX26d p 187 Info The bulb must be positioned with projection in the recess Attach the connector to the bulb and mount the rubber cap Install the headlight mask w...

Page 130: ...urn signal bulb Note Damage to reflector Reduced luminance Grease on the bulb will evaporate due to the heat and be deposited on the reflector Clean the bulb and keep it free of grease before mounting...

Page 131: ...ew and first turn it counterclockwise until it engages in the thread Tighten the screw slightly 9 59 Changing the tail light bulb Note Damage to reflector Reduced luminance Grease on the bulb will eva...

Page 132: ...lighting function Position the tail light Mount and tighten the nuts with the washers Guideline Nut tail light M6 8 Nm 5 9 lbf ft 9 60 Changing the brake light bulb Note Damage to reflector Reduced l...

Page 133: ...with the washers Guideline Nut tail light M6 8 Nm 5 9 lbf ft 9 61 Checking the headlamp setting 0 0 A A 0 0 B B 400609 10 On a light colored wall behind a horizontal area make a mark as high as the c...

Page 134: ...uce the light range If you have a heavy payload you will need to correct the headlight range 9 63 Activating deactivating the ignition key Info The orange programming key must only be used for activat...

Page 135: ...tch on the ignition by turning the black ignition key to the position FI Warning lamp MIL lights up switches off and then starts to flash Immobilizer indicator lamp lights up switches off briefly and...

Page 136: ...n FI Warning lamp MIL lights up switches off and then starts to flash Immobilizer indicator lamp lights up switches off briefly and flashes the number of flashes equals the number of functional black...

Page 137: ...urther ignition keys repeat the last 4 steps with the respective ignition key Insert the orange programming key in the ignition lock Switch on the ignition by turning the orange programming key to the...

Page 138: ...storage compartment and swing it to the right Place a cloth between the right fuel tank and the storage compartment to prevent damage 9 65 Installing the storage compartment x 100616 10 Remove the cl...

Page 139: ...and a health hazard Avoid contact between fuel and 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 are...

Page 140: ...cator and fuel pump Pull off hose Disconnect fuel hose connection Info Remaining fuel may run out of the fuel hose Push the hose clamp back and pull fuel hose off of the fuel tap Take off the fuel tan...

Page 141: ...f children Clean the fuel hose connection and check the O ring for damage 100618 11 Position the fuel tank at about the same height as when mounted to connect the hoses and plug in connectors Attach f...

Page 142: ...olant temperature without causing any malfunctions 125 C 257 F 0 0 2 2 0 0 3 3 400619 10 Cooling takes place by means of the air stream and a radiator fan which is controlled by a thermoswitch The low...

Page 143: ...radiator the radiator hoses or other components of the cooling system when the engine is hot Allow the engine and radiator to cool down If you are scalded hold the affected part under cold water immed...

Page 144: ...and MAX If there is no coolant in the compensating tank Check the cooling system for leaks x Info Do not start up the motorcycle Fill bleed the cooling system x p 147 If the coolant level in the compe...

Page 145: ...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 146: ...ng system for leaks x Info Do not start up the motorcycle Fill bleed the cooling system x p 147 Mount the radiator cap 9 71 Checking the antifreeze x Warning Scalding hazard During motorcycle operatio...

Page 147: ...ontal surface 100610 10 Remove radiator cap and the plug from the compensating tank Check the coolant antifreeze 25 45 C 13 49 F If the coolant antifreeze does not meet specifications Correct the cool...

Page 148: ...have come into contact with coolants Keep coolants out of the reach of children Jack up the vehicle on the center stand p 66 Remove the left fuel tank x p 137 100612 10 Place a suitable container unde...

Page 149: ...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 immediately Change clothes that have com...

Page 150: ...at the vent hole and then mount and tighten the bleeder screw immediately Alternative 1 Coolant p 198 Alternative 2 Coolant mixed ready to use p 198 Fill the radiator completely with coolant Mount the...

Page 151: ...p the engine and allow it to cool down When the engine is cool check the coolant level in the radiator and if necessary add coolant Check the coolant level in the compensating tank and if necessary ad...

Page 152: ...he nuts This ensures that all required parts are available when needed 9 75 Installing the radiator guard 0 0 5 5 0 0 1 1 0 0 1 1 0 0 2 2 0 0 3 3 0 0 4 4 100639 10 Place nuts onto tabs of the radiator...

Page 153: ...of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 9 77 Checking rectifying the fluid level of the hydraulic clutch Info...

Page 154: ...n cable play does not meet specifications Adjust the play in the gas Bowden cable x p 153 Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and or death When run...

Page 155: ...Play in gas Bowden cable 3 5 mm 0 12 0 2 in Tighten counter nut 9 80 Checking the engine oil level Jack up the vehicle on the center stand p 66 Danger Danger of poisoning Exhaust gases are poisonous...

Page 156: ...the oil screens x Drain engine oil clean oil screens x p 154 Install the oil filter x p 159 Install the left fuel tank x p 138 Fill up with engine oil x p 159 Install the underride guard x p 110 9 82...

Page 157: ...left fuel tank x p 137 100624 10 Place a suitable container under the engine Remove the oil drain plug with the magnet and seal ring Fully drain the engine oil out of the engine Remove screws and take...

Page 158: ...d move oil line to one side 100627 10 Pull oil sieve out of the oil tank Remove the oil filter x p 158 Clean all oil screens and oil drain plugs with a magnet Clean all sealing surfaces 100628 10 Chec...

Page 159: ...8 lbf ft Slide oil sieve into the engine case with the TOP marking facing up Check the form ring in cover for damage and correct seating Position cover Mount and tighten the screws Guideline Screw cl...

Page 160: ...you scald yourself hold the affected area under cold water immediately Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc sho...

Page 161: ...clean the parts and sealing surface 9 84 Installing the oil filter x 100631 10 Insert oil filter Lubricate the O ring of the oil filter cover Install oil filter cover Mount and tighten the screws Guid...

Page 162: ...50 p 199 External temperature 0 C 32 F Engine oil SAE 5W 40 p 199 Replace the oil dipstick Jack up the vehicle on the center stand p 66 Danger Danger of poisoning Exhaust gases are poisonous and can r...

Page 163: ...p 199 External temperature 0 C 32 F Engine oil SAE 5W 40 p 199 Replace the oil dipstick 9 86 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the en...

Page 164: ...r power output this setting prevents engine damage by hindering spark knocking due to poor fuel quality Possible states Plug in connector disconnected Fuel with an octane rating of 80 to 94 RON can be...

Page 165: ...l with an octane rating of 80 to 94 RON can be used for one tank full p 162 Activate the ignition curve for fuel with an octane rating of 95 or higher ROZ 95 RON 95 PON 91 Connect plug in connector Fi...

Page 166: ...trol unit Flash code of immobilizer indica tor lamp 14 Immobilizer indicator lamp flashes 1x short 1 second pause 4x short Error level condition Malfunction in transponder of black ignition key Flash...

Page 167: ...indicator lamp flashes 3x short 1 second pause 1x short Error level condition Malfunction encryption query from EFI control unit to immobilizer control unit Flash code of immobilizer indica tor lamp 3...

Page 168: ...Heating lambda sensor cylinder 2 sensor 1 interruption short circuit to ground Heating lambda sensor cylinder 2 sensor 1 input signal too high Flash code of warning lamp FI MIL 09 Warning lamp FI MIL...

Page 169: ...t A input signal too low Throttle valve sensor circuit A input signal too high Flash code of warning lamp FI MIL 17 Warning lamp FI MIL flashes 1x long 7x short Error level condition Lambda sensor cyl...

Page 170: ...nal too low Throttle position sensor circuit B input signal too high Flash code of warning lamp FI MIL 02 Warning lamp FI MIL flashes 2x short Error level condition Circuit ignition pulse generator ma...

Page 171: ...el condition Idle control system malfunction in circuit Flash code of warning lamp FI MIL 24 Warning lamp FI MIL flashes 2x long 4x short Error level condition Power supply malfunction in circuit Flas...

Page 172: ...ensor input signal too high Flash code of warning lamp FI MIL 41 Warning lamp FI MIL flashes 4x long 1x short Error level condition Fuel pump control interruption short circuit to ground Fuel pump con...

Page 173: ...t Flash code of warning lamp FI MIL 11 Warning lamp FI MIL flashes 1x long 1x short Error level condition Manifold absolute pressure sensor cylinder 2 input signal too low Manifold absolute pressure s...

Page 174: ...t x Malfunction in CAN bus communica tion Check the CAN bus communication x Combination instrument defective Check the combination instrument x Control unit for electric start lock defective Check the...

Page 175: ...iator fins Foam formation in cooling system Drain the coolant x p 145 Fill bleed the cooling system x p 147 Buckled or damaged radiator hose Change the radiator hose x Fuse FAN blown Change the fuses...

Page 176: ...not func tioning Fuse H L BEAM POSITION blown Change the fuses in the fuse box p 120 Turn signal hazard warning flasher brake light and horn are not functional Fuse HORN BRAKE LIGHT blown Change the f...

Page 177: ...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 motorcycle close off...

Page 178: ...t inaccessible positions in the engine and on the brakes to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 80 Treat bare metal parts except for...

Page 179: ...ith cold water Warm water would enhance the corrosive effects of salt Clean the motorcycle p 175 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with a wax base...

Page 180: ...175 Change the engine oil and filter clean the oil screens x p 154 Check the antifreeze x p 144 Check the tire air pressure p 107 Remove the battery x p 110 Recharge the battery x p 113 Guideline Stor...

Page 181: ...operation after storage Raise the vehicle off of the center stand p 67 Recharge the battery x p 113 Install the battery x p 112 Set the clock p 29 Refuel p 59 Carry out checks before putting into ope...

Page 182: ...20 C 68 F 0 25 0 30 mm 0 0098 0 0118 in Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Crankshaft bearing Sleeve bearing Conrod bearing Sleeve bearing Piston Forged light alloy Piston ring 1 L rin...

Page 183: ...ark plug NGK LKAR8BI9 Spark plug electrode gap 0 8 mm 0 031 in Cooling Water cooling permanent circulation of coolant by water pump Cold start device Electric starter 16 1 Capacity engine oil Engine o...

Page 184: ...M6 10 Nm 7 4 lbf ft Screw bearing bolt in generator cover M6 10 Nm 7 4 lbf ft Loctite 243 Screw camshaft bearing support M6 10 Nm 7 4 lbf ft Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch spring...

Page 185: ...t Loctite 243 Bearing bolt timing chain tensioning rail M8 20 Nm 14 8 lbf ft Loctite 243 Screw camshaft bearing support M8 Step 1 10 Nm 7 4 lbf ft Step 2 18 Nm 13 3 lbf ft Screw clutch cover M8 15 Nm...

Page 186: ...9 lbf ft Plug oil filter housing M14x1 5 15 Nm 11 1 lbf ft Loctite 243 Bleeder flange generator cover M16x1 5 10 Nm 7 4 lbf ft Loctite 243 Plug timing chain tensioner M16x1 5 20 Nm 14 8 lbf ft Rotor...

Page 187: ...in Suspension travel 990 Adventure R Rear 265 mm 10 43 in Brake system Front Double disk brake with floating brake calipers and brake discs Rear Single disc brake with floating brake caliper and brak...

Page 188: ...ded 990 Adventure R 920 mm 36 22 in Ground clearance unloaded 990 Adventure 261 mm 10 28 in Ground clearance unloaded 990 Adventure R 316 mm 12 44 in Weight without fuel approx 990 Adventure 209 kg 46...

Page 189: ...PX26d 12 V 55 W High beam H3 socket PK22s 12 V 55 W Parking light W5W socket W2 1x9 5d 12 V 5 W Instrument lights and indicator lamps LED Turn signal RY10W socket BAU15s 12 V 10 W Tail light WR5W soc...

Page 190: ...A T 90 90 21 M C 54S M S TT Continental TKC 80 150 70 B 18 M C 70Q M S TT Continental TKC 80 Alternative tires to max 160 km h 99 4 mph Additional information is available in the Service section under...

Page 191: ...ull payload 10 clicks Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Full payload 13 clicks Spring preload Preload Adjuster Comfort 5 turns Standard 5 turns Sport 8 turns Full pa...

Page 192: ...de Down 4860 MXMA PA Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Full payload 1...

Page 193: ...CAL DATA FORK 191 Medium standard 4 8 N mm 27 4 lb in Hard 5 0 N mm 28 6 lb in Fork length 935 mm 36 81 in Air chamber length 100 30 20 mm 3 94 1 18 0 79 in Fork oil 655 ml 22 15 fl oz Fork oil SAE 5...

Page 194: ...t 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Rebound damping Comfort 20 clic...

Page 195: ...5 in Shock absorber oil p 200 SAE 2 5 20 2 990 Adventure R Shock absorber part number 12 18 7E 09 Shock absorber WP Suspension PDS 5018 DCC PA Compression damping low speed Comfort 25 clicks Standard...

Page 196: ...mfort 4 turns Standard 4 turns Sport 8 turns Full payload 10 turns Spring rate Soft 130 N mm 742 lb in Medium standard 140 N mm 799 lb in Hard 150 N mm 857 lb in Spring length 265 mm 10 43 in Gas pres...

Page 197: ...nsion M6 4 Nm 3 lbf ft Nut tail light M6 8 Nm 5 9 lbf ft Remaining chassis nuts M6 15 Nm 11 1 lbf ft Remaining chassis screws M6 10 Nm 7 4 lbf ft Screw connection wheel speed sensor front M6 6 Nm 4 4...

Page 198: ...15 Nm 11 1 lbf ft Screw exhaust clamp M8 8 Nm 5 9 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw fuel tank M8 15 Nm 11 1 lbf ft Screw han...

Page 199: ...rew subframe M10x1 25 45 Nm 33 2 lbf ft Loctite 243 Oil drain plug with magnet M12x1 5 25 Nm 18 4 lbf ft Screw bottom shock absorber M14x1 5 80 Nm 59 lbf ft Thread greased Screw top shock absorber M14...

Page 200: ...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 201: ...responding properties KTM recommends Motorex products Fully synthetic engine oil Supplier Motorex Power Synt 4T Engine oil SAE 5W 40 According to JASO T903 MA p 204 SAE p 204 SAE 5W 40 Guideline Use o...

Page 202: ...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...

Page 203: ...SUBSTANCES 201 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91...

Page 204: ...use Specification KTM recommends Motorex products Supplier Motorex Chain Lube 622 Strong Cleaning and polishing materials for metal rubber and plastic Specification KTM recommends Motorex products Su...

Page 205: ...TM recommends Motorex products Supplier Motorex Fett 2000 Motorcycle cleaner Specification KTM recommends Motorex products Supplier Motorex Moto Clean 900 Universal oil spray Specification KTM recomme...

Page 206: ...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 207: ...g 130 Brake linings front brake checking 92 rear brake checking 96 Brakes 55 Braking 55 C Center stand 42 Chain checking for dirt 79 checking for wear 85 cleaning 80 Chain tension adjusting 82 checkin...

Page 208: ...ay 26 E Electric starter button 23 Emergency OFF switch 23 Engine running in 45 Engine number 17 Engine oil adding 161 changing 154 draining 154 refilling 159 Engine oil level checking 153 Environment...

Page 209: ...132 Headlight adjustment checking 131 Headlight flasher switch 20 Headlight mask with headlight installing 125 removing 124 High beam bulb changing 125 Horn button 21 I Ignition curve adjusting to fu...

Page 210: ...first use 44 R Radiator guard installing 150 removing 149 Rear hub rubber dampers checking 105 Rear sprocket engine sprocket checking for wear 84 Rear wheel installing 103 removing 101 Riding 51 star...

Page 211: ...g 129 Technical data chassis 185 188 chassis tightening torques 195 197 engine 180 181 engine tightening torques 182 184 fork 189 191 shock absorber 192 194 Tire air pressure checking 107 Tire conditi...

Page 212: ...INDEX 210 View of vehicle front left side 12 rear right side vehicle differs slightly from photo 14 W Warning of slippery roads 33 Warranty 8 Work rules 9...

Page 213: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 3 2009 Photo Mitterbauer 3211362en 3211362en...

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