KTM 990 Adventure AUS/UK Page 91 Owner'S Manual Download | Manualshive

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MAINTENANCE WORK ON FRAME AND ENGINE

89

9.24

Checking the free travel of the hand brake lever

Warning

Danger of accidents

Brake system failure.

–

If there is no free travel on the hand brake lever, pressure builds up in the front brake circuit. The front brake can fail due to
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)

» If the free travel does not meet specifications:

–

Adjust the free travel of hand brake lever. (

9.25

Adjusting the free travel of the hand brake lever

100556-10

–

Check the free travel of the hand brake lever. (

–

Adjust the free travel of the hand brake lever with the adjustment screw



.

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Summary of Contents for 990 Adventure AUS/UK

Page 1: ...OWNER S MANUAL 2010 990 Adventure EU 990 Adventure AUS UK 990 Adventure R EU 990 Adventure R AUS UK 990 Adventure R FR Art no 3211514en...

Page 2: ......

Page 3: ...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 reserves the right to m...

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: ...25 Combination 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 Comb...

Page 6: ...on damping of the shock absorber 73 Adjusting the rebound damping of the shock absorber 74 Adjusting the spring preload of the shock absorber 76 Bleeding the fork legs 77 Cleaning the dust boots of th...

Page 7: ...nd hanging it to one side x 136 Installing the storage compartment x 137 Removing the left fuel tank x 138 Installing the left fuel tank x 139 Cooling system 141 Checking the coolant level in the comp...

Page 8: ...ICAL DATA ENGINE TIGHTENING TORQUES 184 TECHNICAL DATA CHASSIS 188 Lighting equipment 190 Tires 191 Capacity fuel 191 TECHNICAL DATA FORK 192 990 Adventure 192 990 Adventure R 193 TECHNICAL DATA SHOCK...

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: ...uddy 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 specif...

Page 11: ...ve spring 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 Loct...

Page 12: ...ct 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 le...

Page 13: ...amage 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...

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 400...

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 400914 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: ...e of the motorcy cle Possible states The turn signal indicator lamp flashes green simultaneously with the turn signal The turn signal is switched on The idle speed indicator lamp lights up green The t...

Page 28: ...ights up or flashes red Status or error message for immobilizer alarm system The battery warning lamp lights up red The voltage in the vehicle system is too low 990 Adventure The ABS warning lamp ligh...

Page 29: ...ront wheel with a series production tire The display then changes to the last selected mode 5 16 Combination instrument speedometer 400838 10 The speed is shown in kilometers per hour km h or in miles...

Page 30: ...N 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 400893...

Page 31: ...he 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 simul...

Page 32: ...400840 01 Switch on the ignition by turning the black ignition key to the position ON Press the MODE button repeatedly until the TRIP 1 mode is active Keep the SET button pressed The TRIP 1 display is...

Page 33: ...is active Keep the SET button pressed The TRIP 2 display is set to 0 0 5 23 Combination instrument TRIP F display 400842 01 If the fuel level drops to the reserve mark the display automatically chang...

Page 34: ...25 Setting the temperature unit of measure Condition The motorcycle is standing 400893 14 Switch on the ignition by turning the black ignition key to the position ON Press the MODE button repeatedly...

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: ...ning flasher switch is found to the left of the combination instrument The hazard warning flasher is used to indicate emergency situations Info The hazard warning flasher can be activated or deactivat...

Page 37: ...on key Info The motorcycle is equipped with two fuel tanks and 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 equipp...

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 lever 100525 10 Foot brake lever is located in front of the right footrest The rear brake is activated using the foot brake lever 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: ...e fitted 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 recommende...

Page 47: ...152 Adjust the free travel of hand brake lever p 89 Adjust the basic position of foot brake lever x Get used to handling the motorcycle on a suitable piece of land before making a longer trip Try also...

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: ...the chain p 80 Check the tire condition p 107 Check the tire air pressure p 108 Check the front brake fluid level p 90 Check the rear brake fluid level p 94 Check the front brake linings p 93 Check t...

Page 51: ...in an enclosed 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 components and safe...

Page 52: ...lectric 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 d...

Page 53: ...owly 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 alterations an...

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: ...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 temperature wa...

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 lever 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: ...t when the vehicle is in use 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 o...

Page 60: ...tion OFF 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 so...

Page 61: ...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 immediatel...

Page 62: ...5 3 US gal Super unleaded ROZ 95 RON 95 PON 91 p 204 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: ...aged and free of leaks Check the rear brake fluid level p 94 Check the free travel of the foot brake lever p 93 Check that the shock absorber and fork are leak tight Perform a fork service and shock a...

Page 65: ...nd correct routing x Check the antifreeze and coolant level p 143 Check the wiring harness of the throttle valve body for damage and correct routing x Check the cables for damage and kink free routing...

Page 66: ...is roadworthy and take a test ride Read out the error memory after the test ride using the KTM diagnostics tool x Make the necessary service entries in the KTM DEALER NET and service record x K10N On...

Page 67: ...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 handw...

Page 68: ...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 69: ...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 pa...

Page 70: ...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 f...

Page 71: ...ebound 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 adjust...

Page 72: ...ounterclockwise 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 legs Turn...

Page 73: ...ck 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 sho...

Page 74: ...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 sp...

Page 75: ...d 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 glad to help Info The high speed setting can...

Page 76: ...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 77: ...the number of clicks 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 Rebou...

Page 78: ...n provided Your authorized KTM workshop will be glad to help 100549 10 Turn handwheel counterclockwise as far as it will go Turn it clockwise by the number of turns corresponding to the shock absorber...

Page 79: ...ce the spring preload 9 14 Bleeding the fork legs Jack up the vehicle on the center stand p 65 100536 10 Remove bleeder screws briefly Any excess pressure escapes from the interior of the fork Mount a...

Page 80: ...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 tube of both fork legs Universal oil...

Page 81: ...nd B00115 01 Move the handlebar to the straight ahead position Move the fork legs back and forth in the direction of travel Play should not be detectable on the steering head bearing If there is no de...

Page 82: ...uces 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...

Page 83: ...rning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bearings in transmis...

Page 84: ...Adjust the chain tension p 82 9 20 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary pow...

Page 85: ...ft 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: ...sprocket and engine sprocket 100132 10 Check the rear sprocket and engine sprocket for wear If the rear sprocket or engine sprocket is worn Change the rear sprocket or engine sprocket x Info The rear...

Page 87: ...nce of 18 chain links in the lower 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 chain section 27...

Page 88: ...htness If the chain sliding guard is loose Fully tighten the chain sliding guard Guideline Screw chain sliding guard M6 6 Nm 4 4 lbf ft Loctite 243 B00114 01 Check the chain guide for wear If the chai...

Page 89: ...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 Under...

Page 90: ...rake disc s without delay Your authorized KTM workshop will be glad to help 400618 10 Check the thickness of the front and rear brake discs in several places to ensure that it conforms to measurement...

Page 91: ...eating 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 If the f...

Page 92: ...not make any adjustments while riding 9 26 Checking the 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...

Page 93: ...em 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 contac...

Page 94: ...ines 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 fl...

Page 95: ...ed unserviceable Check the brake linings regularly 100559 10 Check all brake linings on both brake calipers to ensure they have minimum thick ness Minimum thickness 1 mm 0 04 in If the minimum thickne...

Page 96: ...ravel does not meet specifications Adjust the basic position of foot brake lever x 9 30 Checking the rear brake fluid level Warning Danger of accidents Failure of the brake system If the brake fluid l...

Page 97: ...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 contact Avoid contac...

Page 98: ...in applicable regulations Info Never use 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 b...

Page 99: ...gs Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help Note Danger of accidents...

Page 100: ...k 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 65 Bear down on the re...

Page 101: ...crew to push the wheel spindle out of the fork stub Warning Danger of accidents Reduced braking efficiency caused by damaged brake discs Always lay the wheel down in such a way that the brake discs ar...

Page 102: ...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 Check the wheel bearing for damage and wear If the wheel bea...

Page 103: ...Guideline Screw front wheel spindle M25x1 5 45 Nm 33 2 lbf ft Raise the vehicle off of the center stand p 66 Pull the front wheel brake and push down hard on the fork several times to align the fork...

Page 104: ...ing the rear wheel x Jack up the vehicle on the center stand p 65 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 Remove...

Page 105: ...ssible Take the chain off of the rear sprocket and place it on chain sprocket guard Warning Danger of accidents Reduced braking efficiency caused by damaged brake discs Always lay the wheel down in su...

Page 106: ...wheel always operate the foot brake until the pressure point is reached Check the rear hub rubber dampers x p 106 100571 10 Check the wheel bearing for damage and wear If the wheel bearing is damaged...

Page 107: ...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 108: ...e 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 wit...

Page 109: ...g characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Warning Danger of accidents Reduced roa...

Page 110: ...e age of the tires Info The tire s date of manufacture is usually part of the tire markings and is indi cated by the last four digits of the DOT marking The first two digits refer to the week of manuf...

Page 111: ...re 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 sp...

Page 112: ...er 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 spo...

Page 113: ...y Battery acid and battery gases cause serious cauterization Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases...

Page 114: ...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 withou...

Page 115: ...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 a...

Page 116: ...nse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Warning Environmental hazard Battery parts and acid are harmful to the en...

Page 117: ...d 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 destroying...

Page 118: ...rger 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 off...

Page 119: ...ving 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 Guid...

Page 120: ...e 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 c...

Page 121: ...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 Insta...

Page 122: ...ydraulic 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 117 100585 10 Ch...

Page 123: ...cover Tip Place the spare fuse in the storage compartment so that it is available if needed Install the right underride guard p 117 9 50 Changing the fuses in the fuse box Warning Fire hazard The elec...

Page 124: ...ing 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 125: ...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 189 Fuse 58011109115 p 189 I...

Page 126: ...eft 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 an...

Page 127: ...e 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 128: ...light mask with the headlight 100591 10 Connect plug in connector Check the lighting function Position the headlight mask Install the front side cover p 124 Check the headlight setting p 132 9 55 Chan...

Page 129: ...e headlight and attach the spring bar High beam H3 socket PK22s p 190 Info The bulb must be correctly seated at projections Connect the plug in connector and mount the rubber cap Install the headlight...

Page 130: ...ach the spring bar Low beam H7 socket PX26d p 190 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 wi...

Page 131: ...rn signal bulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting...

Page 132: ...w 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 lamp will evap...

Page 133: ...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 lu...

Page 134: ...ng function Position the tail light Mount and tighten nuts with the washers Guideline Nut tail light M6 8 Nm 5 9 lbf ft 9 61 Checking the headlight setting 0 0 A A 0 0 B B 400609 10 Park the vehicle o...

Page 135: ...adjustment Info Turn clockwise to increase the light range turn counterclockwise to reduce the light range If you have a heavy payload you will need to correct the headlight range 9 63 Activating deac...

Page 136: ...on the ignition by turning the black ignition key to the position ON FI Warning lamp MIL lights up switches off and then starts to flash Immobilizer indicator lamp lights up switches off briefly and l...

Page 137: ...on 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 138: ...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 programming key to th...

Page 139: ...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 clo...

Page 140: ...lth 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 areas immedi...

Page 141: ...vel indicator 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...

Page 142: ...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 fu...

Page 143: ...lant 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 lowe...

Page 144: ...tor hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoni...

Page 145: ...not at the required level but the tank is not empty Remove the compensating tank cap Add coolant to the MAX marking Alternative 1 Coolant p 201 Alternative 2 Coolant mixed ready to use p 201 Mount th...

Page 146: ...on The engine is cold Remove the front side cover p 124 Only remove the right side cover 600898 10 Park the motorcycle upright on a horizontal surface Remove cap of the compensating tank Check the coo...

Page 147: ...ntifreeze 25 45 C 13 49 F If the antifreeze does not meet specifications Correct the coolant antifreeze Check the coolant level in the radiator The radiator must be completely filled If the coolant le...

Page 148: ...cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poiso...

Page 149: ...t Mount screw with a new seal ring and tighten it Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft 9 72 Filling bleeding the cooling system x Warning Danger of poisoning Coolant is poisonous and a...

Page 150: ...ghtened Remove bleeder screw 0 0 A A 400663 10 Position the vehicle as shown and secure it against rolling Height difference must be reached Guideline Height difference 50 cm 19 7 in Info To make sure...

Page 151: ...iator cap Lean the vehicle on the side stand Check the coolant level in the compensating tank p 142 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousne...

Page 152: ...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 coolant to marking MA...

Page 153: ...e nuts This ensures that all required parts are available when needed 9 74 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 154: ...f adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 9 76 Checking rectifying the fluid level of the hydraulic clutch Info...

Page 155: ...does not meet specifications Adjust the play in the throttle cable x p 154 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When run...

Page 156: ...rottle cable 3 5 mm 0 12 0 2 in Tighten counter nut 9 79 Checking the engine oil level Jack up the vehicle on the center stand p 65 Danger Danger of poisoning Exhaust gases are poisonous and inhaling...

Page 157: ...engine oil p 163 Replace the oil dipstick 9 80 Changing the engine oil and filter cleaning the oil screens x B00119 01 Drain engine oil clean oil screens x p 155 Install the oil filter x p 161 Instal...

Page 158: ...ated in applicable regulations Info Drain the engine oil only when the engine is warm Remove the underride guard x p 110 Remove the left fuel tank x p 138 100624 10 Place a suitable container under th...

Page 159: ...er stand p 66 Place the vehicle on the side stand Place a suitable container under the engine Remove oil drain plug Fully drain the engine oil out of the engine Remove screws and move oil line to one...

Page 160: ...plug with the magnet and new seal and tighten Guideline Oil drain plug with magnet M12x1 5 25 Nm 18 4 lbf ft 100629 10 Mount oil drain plug with the magnet and new seal ring and tighten Guideline Oil...

Page 161: ...rning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lukewarm wate...

Page 162: ...60 100632 10 Remove screws Take off oil filter cover with the O ring 100630 10 Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thorough...

Page 163: ...9 84 Filling up with engine oil x Info Too little engine oil or poor quality engine oil results in premature wear to the engine 100622 10 The oil must be added in two steps Engine oil 3 0 l 3 2 qt Ext...

Page 164: ...ient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and run it until it reaches operating temperature Six bars of t...

Page 165: ...ted when the engine is warm 100622 10 Remove oil dipstick and add engine oil to the MAX marking Condition External temperature 0 C 32 F Engine oil SAE 10W 50 p 202 Condition External temperature 0 C 3...

Page 166: ...5 or higher can be used 9 87 Adjusting the ignition curve to the fuel quality Switch off the ignition by turning the black ignition key to the position OFF Remove the seat p 66 To activate the ignitio...

Page 167: ...MAINTENANCE WORK ON FRAME AND ENGINE 165 Mount the seat p 67...

Page 168: ...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 169: ...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 170: ...lamp FI MIL flashes 7x short Error level condition Throttle position sensor circuit B input signal too low Throttle position sensor circuit B input signal too high Flash code of warning lamp FI MIL 09...

Page 171: ...ke air temperature sensor input signal too high Flash code of warning lamp FI MIL 14 Warning lamp FI MIL flashes 1x long 4x short Error level condition Ambient air pressure sensor input signal too low...

Page 172: ...dition Power supply malfunction in circuit Flash code of warning lamp FI MIL 25 Warning lamp FI MIL flashes 2x long 5x short Error level condition Side stand circuit fault Flash code of warning lamp F...

Page 173: ...rt Error level condition Fuel pump control interruption short circuit to ground Fuel pump control input signal too high Flash code of warning lamp FI MIL 45 Warning lamp FI MIL flashes 4x long 5x shor...

Page 174: ...ning lamp FI MIL 54 Warning lamp FI MIL flashes 5x long 4x short Error level condition Secondary air valve interruption short circuit to ground Secondary air valve input signal too high Flash code of...

Page 175: ...FI MIL 81 Warning lamp FI MIL flashes 8x long 1x short Error level condition Immobilizer control unit malfunction in circuit Flash code of warning lamp FI MIL 91 Warning lamp FI MIL flashes 9x long 1x...

Page 176: ...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 177: ...the coolant x p 146 Fill bleed the cooling system x p 147 Buckled or damaged radiator hose Change the radiator hose x Fuse FAN blown Change the fuses in the fuse box p 121 Thermostat defective Check t...

Page 178: ...hange the fuses in the fuse box p 121 Turn signal hazard warning flasher brake light and horn are not functional Fuse HORN BRAKE LIGHT blown Change the fuses in the fuse box p 121 Battery discharged I...

Page 179: ...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 180: ...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 181: ...clean it with cold water Warm water would enhance the corrosive effects of salt Clean the motorcycle p 177 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with...

Page 182: ...p 177 Change the engine oil and filter clean the oil screens x p 155 Check the antifreeze x Check the tire air pressure p 108 Remove the battery x p 111 Recharge the battery x p 114 Guideline Storage...

Page 183: ...operation after storage Raise the vehicle off of the center stand p 66 Recharge the battery x p 114 Install the battery x p 113 Set the clock p 29 Refuel p 59 Carry out checks before putting into ope...

Page 184: ...t 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 ri...

Page 185: ...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 186: ...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 187: ...g chain guide rail M8 15 Nm 11 1 lbf ft 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...

Page 188: ...2nd cylinder M12x1 5 25 Nm 18 4 lbf ft Spark plug M12x1 5 12 Nm 8 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 Loctit...

Page 189: ...TECHNICAL DATA ENGINE TIGHTENING TORQUES 187 Nut primary gear M33LHx1 5 130 Nm 95 9 lbf ft Loctite 243...

Page 190: ...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 191: ...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 192: ...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 193: ...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 194: ...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 195: ...Up Side 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 pay...

Page 196: ...TA FORK 194 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 per fork leg 655 ml 22 15 fl oz Fork oil...

Page 197: ...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 198: ...5 in Shock absorber oil p 203 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 199: ...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 200: ...6 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 lbf ft...

Page 201: ...18 4 lbf ft Screw bottom triple clamp M8 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...

Page 202: ...9 lbf ft Loctite 243 Screw 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...

Page 203: ...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 204: ...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 207 SAE p 207 SAE 5W 40 Guideline Use o...

Page 205: ...fluid 15 According to ISO VG 15 Guideline Use only hydraulic fluid that complies with the specified standards see specifications on the container and that possesses the corre sponding properties KTM r...

Page 206: ...SUBSTANCES 204 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91...

Page 207: ...road use Guideline KTM recommends Motorex products Supplier Motorex Chain Lube 622 Strong Cleaning and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Suppl...

Page 208: ...KTM recommends Motorex products Supplier Motorex Fett 2000 Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Universal oil spray Guideline KTM recommends Mo...

Page 209: ...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 210: ...brake checking 90 rear brake checking 94 Brake light bulb changing 131 Brake linings front brake checking 93 rear brake checking 97 Brakes 55 Braking 55 C Center stand 42 Chain checking 84 checking f...

Page 211: ...ank checking 142 Cooling system 141 filling bleeding 147 D Display 26 E Electric starter button 23 Emergency OFF switch 23 Engine running in 45 Engine number 17 Engine oil adding 163 changing 155 drai...

Page 212: ...Headlight light range adjusting 133 Headlight adjustment checking 132 Headlight flasher switch 20 Headlight mask with headlight installing 126 removing 125 High beam bulb changing 126 Horn button 21...

Page 213: ...ormation on first use 44 R Radiator guard installing 151 removing 150 Rear hub rubber dampers checking 106 Rear sprocket checking 84 Rear wheel installing 104 removing 102 Riding 51 starting up 51 S S...

Page 214: ...6 T Tachometer 25 Tail light bulb changing 130 Technical data chassis 188 191 chassis tightening torques 198 200 engine 182 183 engine tightening torques 184 187 fork 192 194 shock absorber 195 197 Ti...

Page 215: ...INDEX 213 loading 46 raising off of center stand 66 View of vehicle front left side 12 rear right side 14 W Warning of slippery roads 33 Warranty 8 Work rules 9...

Page 216: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 10 2009 Photo Mitterbauer 3211514en 3211514en...

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