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KTM 990 Adventure AUS 2009, Owner'S Manual

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KTM 990 Adventure AUS 2009 Owner'S Manual Download Page 212

front left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
rear right side (vehicle differs slightly from photo) . . . . . . . 14

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Summary of Contents for 990 Adventure AUS 2009

Page 1: ......

Page 2: ......

Page 3: ...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 right to modify or...

Page 4: ...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 to the ma...

Page 5: ...ent 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 instrument set...

Page 6: ...ber 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 absorber 75...

Page 7: ...ating 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 left...

Page 8: ...ty 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 Adventure...

Page 9: ...ical 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 s...

Page 10: ...an 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 the ser vice...

Page 11: ...nter 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 is used for screw...

Page 12: ...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 legally di...

Page 13: ...e measures are not taken Identifies a danger that will lead to environmental damage if the appropriate measures are not taken Be sure to read this owner s manual carefully and completely before taking...

Page 14: ...100540 10...

Page 15: ...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: ...100541 10...

Page 17: ...rn 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 Foot brake...

Page 18: ...he chassis number is stamped on the right side of the steering head The chassis number is also found on the type label 100543 10 The type label is located on the right frame tube in the vicinity of th...

Page 19: ...n 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 for learning and programming functi...

Page 20: ...100545 10 The fork part number is stamped on the inner side of the fork stub 100546 10 The shock absorber part number is stamped on the upper part of the shock absorber...

Page 21: ...s fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 100506 10 The hand brake lever is fitted on the right side of the handlebar The front brake is engage...

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 100508 10 The headlight flasher switch is fitted on the left side of...

Page 23: ...tral 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 turn signal...

Page 24: ...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 100501 10 The electronic immobilizer secur...

Page 25: ...47 10 The emergency OFF switch is fitted on the right side of the handlebar Emergency OFF switch off In this position the ignition circuit is inter rupted a running engine stops and the engine cannot...

Page 26: ...tons Tachometer Indicator lamps Display 100492 10 You can change the display mode with the button Possible display modes are the distance traveled trip master 1 trip mas ter 2 and the ambient temperat...

Page 27: ...nal indicator lamp flashes green simultaneously with the turn signals The turn signal is switched on The idle speed indicator lamp lights up green The transmission is switched to idle The high beam in...

Page 28: ...zer indicator 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 li...

Page 29: ...the circumference of the 21 front wheel with a series production tire The display then changes to the last selected mode 100503 10 The speed is shown in kilometers per hour or in miles per hour If yo...

Page 30: ...ion key to the position Press the button repeatedly until the mode is active Keep the button pressed until the display mode changes from to or from to 100502 10 The time is shown in area of the displa...

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

Page 32: ...at again 700121 01 Switch on the ignition by turning the black ignition key to the position Press the button repeatedly until the mode is active Keep the button pressed The display is set to The trip...

Page 33: ...n repeatedly until the mode is active Keep the button pressed The display is set to 100499 10 If the fuel level drops to the reserve mark the display automatically changes to and starts to count from...

Page 34: ...F The motorcycle is standing 100500 11 Switch on the ignition by turning the black ignition key to the position Press the button repeatedly until the ambient temperature is active Keep the button pre...

Page 35: ...he display when the ambient temperature rises above the specified value again Temperature 4 C 39 F 400617 01 The temperature display consists of 12 bars The more bars that light up the hotter the cool...

Page 36: ...ation instrument The hazard warning flasher is used to signal an emergency situation and to warn other road users Activate deactivate the hazard warning flasher with the ignition switched on or no mor...

Page 37: ...two 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 100515 10 Fuel is highly flammable...

Page 38: ...ocks the seat and locks and unlocks the storage compartment Storage compartment locked Storage compartment unlocked Seat unlocked The seat lock can be locked with the ignition key 100518 10 Insert the...

Page 39: ...rn the ignition key to position Remove the ignition key 100520 10 Unlock the storage compartment p 36 Press button toward the seat and raise the cover at the same time The storage compartment can only...

Page 40: ...torage compartment can be opened again as long as it has not been locked using the seat lock Lock the storage compartment p 37 100522 10 The handrails are used for moving the motorcycle around When yo...

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

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

Page 43: ...st and second gears 100528 10 Side stand is coupled with the safety start system see the riding instructions Side stand folded out The vehicle can be leaned on the side stand The safety start system i...

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

Page 45: ...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: ...imilar tread patterns to prevent loss of control over the vehicle Uncontrollable handling characteristics due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and...

Page 47: ...e 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 also to ride as...

Page 48: ...t 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 Risk of breakage of suitcase system If you...

Page 49: ...t 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 distri bution between the front and rear wheels Do no...

Page 50: ...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 fluid level p 93 Check the front br...

Page 51: ...run the engine in a closed space without an effective exhaust extraction system If the vehicle is operated with a discharged battery or without a battery electronic components and safety equipment ma...

Page 52: ...button Do not press the electric starter button until the function test of the combination instrument is finished When starting open the throttle If you open the throttle during the start ing procedu...

Page 53: ...ase the clutch lever slowly and simultaneously open the throttle carefully Abrupt load alterations can cause the vehicle to get out of control Avoid abrupt load alterations and sudden braking actions...

Page 54: ...ly as possible Reduced road grip with cold tires On every journey take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured Reduced...

Page 55: ...without an air filter since dust and dirt can get into the engine and result in increased wear Overheating of engine If the coolant temperature warning lamp lights up stop and switch off the engine A...

Page 56: ...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 time...

Page 57: ...nently The rear brake can fail due to overheating Take your foot off the foot brake pedal if you do not want to brake Longer stopping distance due to higher overall weight Take the longer stopping dis...

Page 58: ...face 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 Braking should always be completed be...

Page 59: ...n 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 The parked vehicle can roll away or fall...

Page 60: ...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 discharged...

Page 61: ...act 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 immediately with soap and w...

Page 62: ...rox 20 l 5 3 US gal Super unleaded ROZ 95 RON 95 PON 91 p 201 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 Cl...

Page 63: ...s the button for two seconds The fuel level warning lamp switches off is set to and appears in the previous display mode If you do not press the button the reset takes place automatically after about...

Page 64: ...ult memory using the KTM diagnostics tool x Perform a status query with the KTM diagnostics tool for the neutral gear clutch 2nd 3rd gear and the side stand switch x Check the connection boots for cra...

Page 65: ...al 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 brake linings p 92 Ch...

Page 66: ...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 sprocket engine s...

Page 67: ...the steering head bearing and sealing elements x Clean the battery poles and treat with contact grease x Change the coolant x after 15 000 km 9 320 mi every 15 000 km 9 320 mi after every sporting use...

Page 68: ...e could be damaged and the motorcycle could fall over Pull the motorcycle up onto the center stand using the handrail and not the handwheel of the shock absorber adjustment The shock absorber could be...

Page 69: ...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 stand is folded all the way up 100516 10 Ins...

Page 70: ...that the seat is correctly mounted 100532 10 The fork and the shock absorber offer many options of adapting the suspension to your rid ing style and the payload To help you adapt the vehicle we have...

Page 71: ...s 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 fork type Guideline Compression damp...

Page 72: ...ound behavior 100534 10 Turn adjusting screws clockwise until they stop The adjusting screws are located at the top end of the fork legs Make the same adjustment on both fork legs Turn back counterclo...

Page 73: ...n damping turn counterclockwise to reduce damping 100535 10 Turn the adjusting screws counterclockwise until they stop Make the same adjustment on both fork legs Turn back clockwise by the number of t...

Page 74: ...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 shock absorber dur...

Page 75: ...as the last perceptible click Do not loosen nut Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Compression damping low speed Comfort 25 clicks St...

Page 76: ...sity nitrogen Adhere to the description provided Your authorized KTM workshop will be pleased to help The high speed setting can be seen during the fast compression of the shock absorber 100538 10 Tur...

Page 77: ...rt 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Turn clockwise to increase damping turn counterclockwise to reduce suspension damping Disassembly of pressurized parts can lead to injury...

Page 78: ...s corresponding to the shock absorber type Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sp...

Page 79: ...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 absorber type and use Guideline Sprin...

Page 80: ...clockwise to reduce the spring preload 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 and tighten...

Page 81: ...aking 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 dust boots and inner fork...

Page 82: ...cleaner when necessary Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations The service life...

Page 83: ...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 0 B B 0 A A 400620 10 Lean the motorcycle on t...

Page 84: ...ear wheel are under additional load Apart from premature wear in extreme cases the chain may snap or the countershaft of the transmission can break On the other hand if the chain is loose it may jump...

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

Page 86: ...f the rear sprocket engine sprocket are worn Change the rear sprocket engine sprocket The engine sprocket rear sprocket and chain should always be changed together For safety reasons the chain has no...

Page 87: ...inks in the upper chain section Chain wear is not always 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 dista...

Page 88: ...eling straight ahead without the action of lateral forces ABS works with two mutually independent brake circuits front and rear brake Under nor mal conditions the brake system works like a conventiona...

Page 89: ...rkshop 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 measurement Wear reduces the thickness of the brake disc...

Page 90: ...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 If the free travel does not meet spe...

Page 91: ...o not apply any force Do not make any adjustments while riding Failure of the brake system If the brake fluid level falls below the mark this indicates a leakage in the brake system or worn out brake...

Page 92: ...heck the brake system and do not continue riding Your authorized KTM workshop will be pleased to help Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of...

Page 93: ...ake 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 fluid reservoir mounted on the handl...

Page 94: ...dered 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 than specified Change the...

Page 95: ...ake pedal If the free travel does not meet specifications Adjust the basic position of the footbrake lever x Failure of the brake system If the brake fluid level falls below the mark this indicates a...

Page 96: ...system and do not continue riding Your authorized KTM workshop will be pleased to help Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of c...

Page 97: ...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 brake fluid and painted parts Brake fl...

Page 98: ...ng efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be pleased to help Reduced braking efficiency caused by damaged brake discs If the br...

Page 99: ...heck the brake linings for damage and cracking If there is wear or tearing Change the rear brake linings x x Jack up the vehicle on the center stand p 66 Load the vehicle down at the rear or jack it u...

Page 100: ...to push the wheel spindle out of the fork stub Reduced braking effect caused by damaged brake discs Always lay the wheel down in such a way that the brake discs are not dam aged Holding the front whee...

Page 101: ...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 grease the shaft seal rings and bearing surface of...

Page 102: ...nt 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 legs Fully tighten s...

Page 103: ...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 Remove screw and pull wheel speed sensor out of...

Page 104: ...ible Take the chain off of the rear sprocket and place it on chain sprocket guard Reduced braking due to damaged brake discs Always lay the wheel down in such a way that the brake disc is not damaged...

Page 105: ...operate the footbrake until the pressure point is reached Check the rear hub rubber dampers x p 105 100571 10 Clean and grease shaft seal ring and bearing surface of the distance bushing Long life gr...

Page 106: ...g 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 reference marks N...

Page 107: ...e 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 with the rear sprocket facing upwards and ins...

Page 108: ...res wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Reduced road grip with new tires New tires have a smooth rolling surface and therefore cannot provide...

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

Page 110: ...e pressure does not meet specifications Correct the tire pressure Mount the dust cap Instable handling due to incorrect spoke tension Ensure that the spoke tension is correct Your authorized KTM works...

Page 111: ...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 spoke ten...

Page 112: ...ries 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 flames Charge only in well v...

Page 113: ...connect the positive plus cable of the battery Take the battery out of the battery compartment with battery tray Never operate the motorcycle with a discharged battery or without a battery In both cas...

Page 114: ...e 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 and swing up Mount and tighten screw...

Page 115: ...ounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Battery parts and acid are harmful to the environment Do not discard batteries with the...

Page 116: ...icle 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 destroying the battery The batter...

Page 117: ...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 off and disconnect the c...

Page 118: ...100581 10 Remove screws Remove the right underride guard 100581 11 Position right underride guard Mount and tighten screws Guideline Remaining chassis screws M6 10 Nm 7 4 lbf ft...

Page 119: ...he prescribed amperage Never by pass or repair fuses The main fuse is located in the starter relay under the right underride guard Switch off all power consumers and the engine Remove the right underr...

Page 120: ...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 Install a new main fuse Fuse 58011109130 p...

Page 121: ...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 Remove protective cover and re...

Page 122: ...ce the spare fuse in the storage compartment so that it is available if needed Install the right underride guard p 116 The electrical system can be overloaded by the use of incorrect fuses Use only fu...

Page 123: ...low beam parking light license plate lamp Fuse 10A horn brake light hazard warning flasher Fuse 10A radiator fan Fuse 10A ignition EFI control unit Fuse 10A combination instrument socket supplementar...

Page 124: ...e spare fuse in the fuse box so that it is available if needed 100637 10 Use spare fuses with the correct rating only Fuse 58011109110 p 186 Fuse 58011109115 p 186 Spare fuses are located next to the...

Page 125: ...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 and take off the trim...

Page 126: ...of the 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 sig...

Page 127: ...ing damaged 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 Reduced luminance Grease on...

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

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

Page 130: ...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 100597 10 Remove the screw on the rear of the t...

Page 131: ...e screw and first turn it counterclockwise until it engages in the thread Tighten the screw slightly Reduced luminance Grease on the bulb will evaporate due to the heat and be deposited on the reflect...

Page 132: ...heck the 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 Reduced luminance Grease on the bulb will evaporate due to th...

Page 133: ...ith the washers Guideline Nut tail light M6 8 Nm 5 9 lbf ft 0 A A 0 B B 400609 10 On a light colored wall behind a horizontal area make a mark as high as the center of the low beam headlight Make anot...

Page 134: ...nge If you have a heavy payload you will need to correct the headlight range The orange programming key must only be used for activating and deactivating If a black ignition key is lost or replaced th...

Page 135: ...key to the position Warning lamp lights up switches off and then starts to flash Immobilizer indicator lamp lights up switches off briefly and lights up again Switch off the ignition by turning the bl...

Page 136: ...hes 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 ignition keys includ ing the orange p...

Page 137: ...o activate further 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 programmin...

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 x 100616 10 Remove the cloth and position the storage compartment...

Page 139: ...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 immediately with soap and water If fuel is swallowed conta...

Page 140: ...l indicator and fuel pump Pull off hose Disconnect fuel hose connection 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 ta...

Page 141: ...ection 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 fuel hose to the fuel tap and push t...

Page 142: ...ing any malfunctions 125 C 257 F 0 2 2 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...

Page 143: ...f 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 immediately Coolants are poisonous and a health hazard...

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

Page 145: ...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 come into contact with coolants Keep...

Page 146: ...for leaks x Do not start up the motorcycle Fill bleed the cooling system x p 147 Mount the radiator cap x During motorcycle operation the coolant gets very hot and is under pressure Do not open the r...

Page 147: ...ce 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 coolant antifre...

Page 148: ...s 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 under the radiator Remove screw Remove...

Page 149: ...t a doctor 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 coolants out of t...

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

Page 151: ...he 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 add c...

Page 152: ...he nuts This ensures that all required parts are available when needed 0 5 5 0 1 1 0 1 1 0 2 2 0 3 3 0 4 4 100639 10 Place nuts onto tabs of the radiator Hook radiator guard into holes at the bottom a...

Page 153: ...s limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding The fluid level rises with increasing wear of the clutch lining disc Do not use brak...

Page 154: ...ifications Adjust the play in the gas Bowden cable x p 153 Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine always make sure there is sufficient venti...

Page 155: ...owden cable 3 5 mm 0 12 0 2 in Tighten counter nut Jack up the vehicle on the center stand p 66 Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine alway...

Page 156: ...dipstick 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 x Engine oil...

Page 157: ...00624 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 off cover Pull the oil...

Page 158: ...e 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 Check seal ring of the oi...

Page 159: ...sieve into the engine case with the marking facing up Check the form ring in cover for damage and correct seating Position cover Mount and tighten the screws Guideline Screw clutch cover M6 10 Nm 7 4...

Page 160: ...fected area under cold water immediately Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations...

Page 161: ...l Thoroughly clean the parts and sealing surface x 100631 10 Insert oil filter Lubricate the O ring of the oil filter cover Install oil filter cover Mount and tighten the screws Guideline Remaining en...

Page 162: ...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 Exhaust gases are poisonous and can result in unconsciousness and or dea...

Page 163: ...50 p 199 External temperature 0 C 32 F Engine oil SAE 5W 40 p 199 Replace the oil dipstick Too little engine oil or poor quality engine oil results in premature wear to the engine The engine oil level...

Page 164: ...e will have a slightly lower power output this setting prevents engine damage by hindering spark knocking due to poor fuel quality Plug in connector disconnected Fuel with an octane rating of 80 to 94...

Page 165: ...connector disconnected Fuel with an octane rating of 80 to 94 RON can be used for one tank full p 162 Connect plug in connector Figure 100554 10 p 162 Plug in connector connected Fuel with an octane...

Page 166: ...of immobilizer control unit 14 Immobilizer indicator lamp flashes 1x short 1 second pause 4x short Malfunction in transponder of black ignition key 15 Immobilizer indicator lamp flashes 1x short 1 se...

Page 167: ...Immobilizer indicator lamp flashes 3x short 1 second pause 1x short Malfunction encryption query from EFI control unit to immobilizer control unit 32 Immobilizer indicator lamp flashes 3x short 1 seco...

Page 168: ...sensor cylinder 2 sensor 1 interruption short circuit to ground Heating lambda sensor cylinder 2 sensor 1 input signal too high 09 Warning lamp flashes 9x short Manifold absolute pressure sensor cyli...

Page 169: ...lve sensor circuit A input signal too low Throttle valve sensor circuit A input signal too high 17 Warning lamp flashes 1x long 7x short Lambda sensor cylinder 1 sensor 1 malfunction in circuit 18 War...

Page 170: ...cuit B input signal too low Throttle position sensor circuit B input signal too high 02 Warning lamp flashes 2x short Circuit ignition pulse generator malfunction in circuit 37 Warning lamp flashes 3x...

Page 171: ...lamp flashes 4x long 9x short Idle control system malfunction in circuit 24 Warning lamp flashes 2x long 4x short Power supply malfunction in circuit 50 Warning lamp flashes 5x long Throttle position...

Page 172: ...nt air pressure sensor input signal too high 41 Warning lamp flashes 4x long 1x short Fuel pump control interruption short circuit to ground Fuel pump control input signal too high 25 Warning lamp fla...

Page 173: ...unction in circuit 11 Warning lamp flashes 1x long 1x short Manifold absolute pressure sensor cylinder 2 input signal too low Manifold absolute pressure sensor cylinder 2 input signal too high 91 Warn...

Page 174: ...n Check the CAN bus communication x Combination instrument defective Check the combination instrument x Control unit for electric start lock defective Check the control unit of the electric start lock...

Page 175: ...or 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 blown Change the fuses in the...

Page 176: ...ot func tioning Fuse blown Change the fuses in the fuse box p 120 Turn signal hazard warning flasher brake light and horn are not functional Fuse blown Change the fuses in the fuse box p 120 Battery d...

Page 177: ...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 the exhaust system to prevent penetration b...

Page 178: ...s 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 brake discs and exhaus...

Page 179: ...ce 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 based anti corrosion substance To prevent...

Page 180: ...e 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 Storage temperatu...

Page 181: ...aise 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 operation p 48 Take a test ri...

Page 182: ...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 ring 1 tapered c...

Page 183: ...V 450 W Spark 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 Engine oil 3 0 l 3 2 q...

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

Page 185: ...ning rail M8 20 Nm 14 8 lbf ft 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 11 1 lbf ft Stud exhaust flange M8 15 Nm 11 1 lbf ft Beari...

Page 186: ...lug M12x1 5 12 Nm 8 9 lbf ft Plug oil filter housing M14x1 5 15 Nm 11 1 lbf ft Bleeder flange generator cover M16x1 5 10 Nm 7 4 lbf ft Plug timing chain tensioner M16x1 5 20 Nm 14 8 lbf ft Rotor screw...

Page 187: ...venture 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 brake disc Brake system 990 Adve...

Page 188: ...ure 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 461 lb Weight wi...

Page 189: ...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 socket W2 1x9 5d 12 V 5 W Bra...

Page 190: ...0 Continental TKC 80 Alternative tires to max 160 km h 99 4 mph Additional information is available in the Service section under http www ktm com Total fuel tank capacity approx 20 l 5 3 US gal Super...

Page 191: ...s Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Full payload 13 clicks Spring preload Comfort 5 turns Standard 5 turns Sport 8 turns Full payload 7 turns Spring length with prel...

Page 192: ...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 13 clicks Spring prelo...

Page 193: ...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 p 200...

Page 194: ...licks 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 clicks Standard 15 clicks Spo...

Page 195: ...5 in Shock absorber oil p 200 SAE 2 5 Shock absorber part number 12 18 7E 09 Shock absorber PDS 5018 DCC PA Compression damping low speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payl...

Page 196: ...urns 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 pressure 10 bar 145 psi Static...

Page 197: ...ension 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: ...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 Screw fuel tank M8 15 Nm 11 1 lbf ft Screw handlebar clamp M8 20 Nm 1...

Page 199: ...il 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 M14x1 5 80 Nm 59 lbf ft Thread greased Nut socket M18x1...

Page 200: ...the corre sponding properties KTM recommends and products Use only suitable coolant also in countries with high temperatures Use of low quality antifreeze can lead to corrosion and foaming KTM recomme...

Page 201: ...tainer and that possess the corresponding properties KTM recommends products Fully synthetic engine oil JASO T903 MA p 204 SAE p 204 SAE 5W 40 Use only engine oils that comply with the specified stand...

Page 202: ...commends products ISO VG 15 Use only hydraulic fluid that complies with the specified standards see specifications on the container and that possesses the corre sponding properties KTM recommends prod...

Page 203: ...DIN EN 228 ROZ 95 RON 95 PON 91...

Page 204: ...KTM recommends products KTM recommends products KTM recommends products KTM recommends products...

Page 205: ...KTM recommends products KTM recommends products KTM recommends products...

Page 206: ...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 the same o...

Page 207: ...ng 130 front brake checking 92 rear brake checking 96 55 55 42 checking for dirt 79 checking for wear 85 cleaning 80 adjusting 82 checking 81 16 175 176 fluid level checking rectifying 151 adjusting 1...

Page 208: ...ng 141 radiator checking 143 filling bleeding 147 26 23 23 running in 45 17 adding 161 changing 154 draining 154 refilling 159 checking 153 10 closing 35 opening 35 fuel 59 engine control 166 171 immo...

Page 209: ...justing 88 free travel checking 88 38 34 34 light range adjusting 132 checking 131 20 installing 125 removing 124 changing 125 21 adjusting to fuel quality 162 plug in connector 162 activating deactiv...

Page 210: ...n 48 information on first use 44 installing 150 removing 149 checking 105 checking for wear 84 installing 103 removing 101 starting up 51 mounting 68 removing 67 36 62 65 40 51 compression damping gen...

Page 211: ...36 25 changing 129 chassis 185 188 chassis tightening torques 195 197 engine 180 181 engine tightening torques 182 184 fork 189 191 shock absorber 192 194 checking 107 checking 106 43 9 172 174 changi...

Page 212: ...front left side 12 rear right side vehicle differs slightly from photo 14 33 8 9...

Page 213: ...5230 Mattighofen Austria 3 2009 Photo Mitterbauer 3211362en 3211362en...

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