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KTM 990 Adventure AUS, Owner'S Manual, Page: 166 / 218

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KTM 990 Adventure AUS Owner'S Manual Download Page 166

SERVICE WORK ON THE ENGINE

164

Warning

Environmental hazard

 

Hazardous substances cause environmental damage.

–

Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Condition

The underride guard has been removed.

–

Place a suitable container under the engine.

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.

–

Thoroughly clean the parts and sealing surface.

Summary of Contents for 990 Adventure AUS

Page 1: ...OWNER S MANUAL 2011 990 Adventure EU 990 Adventure AUS UK 990 Adventure R EU 990 Adventure R AUS UK 990 Adventure R FR Art no 3211657en...

Page 2: ......

Page 3: ...However it is never possible to exclude small deviations arising from further development in design and construction All specifications are non binding KTM Sportmotorcycle AG specifically reserves th...

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

Page 5: ...bination 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 Combinatio...

Page 6: ...k absorber 74 SERVICE WORK ON THE CHASSIS 76 Raising the vehicle using the center stand 76 Raising the vehicle off of the center stand 77 Bleeding the fork legs 77 Cleaning the dust boots of the fork...

Page 7: ...uses in the fuse box 130 Removing the headlight mask with the headlight 132 Installing the headlight mask with the headlight 134 Changing the low beam bulb 134 Changing the high beam bulb 135 Changing...

Page 8: ...BLINK CODE 178 TECHNICAL DATA ENGINE 184 Capacity engine oil 185 Capacity coolant 185 TECHNICAL DATA ENGINE TIGHTENING TORQUES 186 TECHNICAL DATA CHASSIS 190 Lighting equipment 192 Tires 193 Capacity...

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

Page 10: ...such as very muddy 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 t...

Page 11: ...ses Ex valve 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 Where thread lo...

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 B00550 10...

Page 15: ...ver p 19 2 Tool set p 44 3 Seat lock p 37 4 Luggage rack plate p 40 5 Handrails p 39 6 Fork compression adjustment 7 Fuel taps p 40 8 Side stand p 42 9 Shift lever p 41 10 Footrest 11 Center stand p 4...

Page 16: ...VIEW OF VEHICLE 14 3 2 View of vehicle rear right side vehicle differs slightly from photo B00551 10...

Page 17: ...er switch p 20 3 Hazard warning flasher switch hazard warning flasher p 34 4 Socket for electrical accessories p 34 5 Emergency OFF switch p 23 5 Electric starter button p 23 6 Hand brake lever p 19 7...

Page 18: ...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 frame...

Page 19: ...700222 01 The key number Code number can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place Use the orange programming key to activate...

Page 20: ...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 part of...

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: ...he 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 transmi...

Page 28: ...r lamp lights 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 l...

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: ...on ON 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 40...

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: ...s 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 changes...

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: ...er and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc tor immediately Change clothing that has come into contact with fuel Store fuel in a...

Page 38: ...are equipped with a ventilation system 5 31 Closing the filler caps 100515 10 Warning Fire hazard Fuel is highly flammable poisonous and harmful to your health When closing the filler cap ensure that...

Page 39: ...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 40: ...Turn the ignition key to position Remove the ignition key 5 35 Opening the storage compartment 100520 10 Unlock the storage compartment p 37 Press button toward the seat and raise the cover at the sa...

Page 41: ...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 38 5 37 Handrails B00553 10 The handrails are used for m...

Page 42: ...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 43: ...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 44: ...e vehicle The side stand is used for parking the motorcycle Info The side stand must be folded up during motorcycle use Side stand is coupled with the safety start system see the riding instructions P...

Page 45: ...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 46: ...CONTROLS 44 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 47: ...ashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control ov...

Page 48: ...ervice record at vehicle handover Before your first trip read the entire operating instructions carefully Get to know the controls Adjust the basic setting of the clutch lever p 95 Adjust the free tra...

Page 49: ...lmet baggage Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and or tank rucksack Mount and secure suitcase and tank rucksack according to the manuf...

Page 50: ...ble handling characteristics due to slipped baggage Check the way your baggage is fixed regularly Warning Danger of burns A hot exhaust system can burn baggage Fasten your baggage in such a way that i...

Page 51: ...vel p 105 Check the front brake linings p 104 Check the rear brake linings p 108 Check that the brake system is functioning properly Check the coolant level in the compensating tank p 154 Check the ch...

Page 52: ...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 53: ...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 54: ...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 55: ...er early on 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 optimal road...

Page 56: ...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 57: ...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 58: ...drag continuously The rear brake may fail due to overheating Take your foot off the foot brake lever when you are not braking Warning Danger of accidents Longer stopping distance due to higher overal...

Page 59: ...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 60: ...t when the vehicle is operated 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...

Page 61: ...ion 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 soo...

Page 62: ...tor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc tor immediately Change clothing that has come into contact with fuel Note Material damage Premature clog...

Page 63: ...5 3 US gal Super unleaded ROZ 95 RON 95 PON 91 p 206 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 64: ...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 65: ...e linings p 108 Check the brake discs p 100 Check that the brake lines are undamaged and free of leaks Check the rear brake fluid level p 105 Check the free travel of the foot brake lever p 104 Check...

Page 66: ...ifreeze and coolant level p 147 Check the wiring harness of the throttle valve body for damage and correct routing x Check the cables for damage and kink free routing x Check the control cables for da...

Page 67: ...e vehicle 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...

Page 68: ...ersonal suspension adaptation Do not change the adjustments at random or by more than 40 since otherwise the riding characteristics could deteriorate particularly at high speeds 9 2 Adjusting the comp...

Page 69: ...cks 990 Adventure R Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping Moun...

Page 70: ...s Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline 990 Adventure Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Full payload 13 clicks...

Page 71: ...e adjustment on both fork legs Turn back clockwise by the number of turns corresponding to the fork type Guideline 990 Adventure Spring preload Preload Adjuster Comfort 5 turns Standard 5 turns Sport...

Page 72: ...the landing after a jump the rear wheel suspension compresses more quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses mor...

Page 73: ...clicks corresponding to the shock absorber type Guideline 990 Adventure Compression damping low speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks 990 Adventure R Compr...

Page 74: ...vided Your authorized KTM workshop will be glad to help Info The high speed setting can be seen during the fast compression of the shock absorber 100538 10 Turn adjusting screw clockwise all the way u...

Page 75: ...d damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provid...

Page 76: ...licks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 9 9 Adjusting the spring preload of the shock absorber Caution Danger of ac...

Page 77: ...e 990 Adventure Spring preload Preload Adjuster Comfort 4 turns Standard 4 turns Sport 8 turns Full payload 16 turns 990 Adventure R Spring preload Preload Adjuster Comfort 4 turns Standard 4 turns Sp...

Page 78: ...le 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 handwheel...

Page 79: ...ward 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 stand is folded all the way up 10...

Page 80: ...braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Clean and oil the dust boots and inner f...

Page 81: ...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 detectable play Adjust the steering head bearing play x...

Page 82: ...ont side cover Info The operations are the same on the left and right sides 100589 11 Position side cover at the fuel tank on the bottom and hold it at an angle Attach the overflow hose of the fuel ta...

Page 83: ...the radiator guard 100641 10 Remove screws and radiator guard 100642 10 Pull nuts off of the radiator Tip Insert the screws into the holes of the radiator guard and mount the nuts This ensures that a...

Page 84: ...ator Hook radiator guard into holes at the bottom and swing up to the radiator Mount and tighten screws Guideline Remaining chassis nuts M6 15 Nm 11 1 lbf ft 10 10 Removing the seat 100516 10 Insert t...

Page 85: ...g pin into the lock housing and push the back of the seat down until the locking pin locks in place with an audible click Finally check that the seat is correctly mounted 10 12 Removing the storage co...

Page 86: ...Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health h...

Page 87: ...t detach from the upper holder and swing the top away from the vehicle Info Hold the fuel tank at about the same height as when it is mounted Before removing the fuel tank entirely a number of hoses a...

Page 88: ...ng 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 contact a doc t...

Page 89: ...the front side cover p 80 Turn the knurled screws on both fuel taps counterclockwise as far as possible Check the fuel system for leaks 10 16 Checking for chain dirt 400678 01 Check the chain for coar...

Page 90: ...l hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info The service life of the cha...

Page 91: ...On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check the chain tension and correct if necessary 0 0 B B...

Page 92: ...sprocket rear sprocket bearings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can br...

Page 93: ...nd 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 you...

Page 94: ...cket 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 spro...

Page 95: ...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 272 mm...

Page 96: ...ss 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 chain gu...

Page 97: ...ustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 10 22 Checking rectifying the fluid level of the hydraulic clutch Info The...

Page 98: ...ighten the screws 10 23 Removing the right underride guard 100581 10 Remove screws Remove the right underride guard 10 24 Installing the right underride guard 100581 11 Position right underride guard...

Page 99: ...10 Swing the side stand downward Remove all four screws and take off underride guard 10 26 Installing the underride guard x 100578 10 Position underride guard Mount and tighten screws Guideline Screw...

Page 100: ...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 nor mal conditi...

Page 101: ...d 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 overheat...

Page 102: ...ndlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 11 4 Checking the brake discs Warning Danger of acc...

Page 103: ...fluid level Warning Danger of accidents Failure of the brake system If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the b...

Page 104: ...gs Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin...

Page 105: ...d 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 fluid reservoir mounte...

Page 106: ...le 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 thickness is less tha...

Page 107: ...meet specifications Adjust the basic position of foot brake lever x 11 9 Checking the rear brake fluid level Warning Danger of accidents Failure of the brake system If the brake fluid level falls bel...

Page 108: ...brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and...

Page 109: ...able regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painte...

Page 110: ...ger 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 Reduced brakin...

Page 111: ...s for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings x Check the brake linings for damage and cracking If there is wear...

Page 112: ...the rear of the vehicle or raise it on the underride guard The front wheel is not in contact with the ground 100605 10 Press the brake calipers by hand on to the brake discs in order to press back the...

Page 113: ...accidents Reduced braking efficiency 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 wheel withdraw the wheel spindle Swin...

Page 114: ...earing x Clean and grease the shaft seal rings and bearing surface of the spacers Long life grease p 208 Insert the spacers 100604 11 Lift the front wheel into the fork engage the brake discs into the...

Page 115: ...wheel speed sensor and push them into the hole together Mount and tighten screw Guideline Screw connection wheel speed sensor front M6 6 Nm 4 4 lbf ft 12 3 Removing the rear wheel x Raise the vehicle...

Page 116: ...wheel spindle only far enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Take the chain off of the rear sprocket and place it on chain sprocket guard...

Page 117: ...grease and clean them with brake cleaner when necessary Warning Danger of accidents No braking effect when operating the rear brake After installing the rear wheel always operate the foot brake until...

Page 118: ...e rear wheel forward so that the chain adjusters are in contact with the adjust ing screws and tighten nut Guideline In order for the rear wheel to be correctly aligned the markings on the left and ri...

Page 119: ...mpers 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 rear wheel on a workbench with the rear...

Page 120: ...trollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Warning Danger of acci...

Page 121: ...res 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 manufacture and last...

Page 122: ...meet specifications Correct the tire pressure Mount the dust cap 12 8 Checking spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that the spoke tension...

Page 123: ...frequency of the sound is a function of the spoke length and spoke diame ter If spokes of the same length and diameter vibrate with a different tone this is an indication that the spoke tensions diff...

Page 124: ...ontact with battery acid and battery gases Keep the battery away from sparks or open fire Charge only in well ventilated rooms Flush with copious amounts of water in case of skin contact If battery ac...

Page 125: ...ery tray Info Never operate the motorcycle with a discharged battery or without a battery In both cases electrical components and safety equipment can be damaged The vehicle is then no longer safe to...

Page 126: ...ith battery acid and battery gases Keep the battery away from sparks or open fire Charge only in well ventilated rooms Flush with copious amounts of water in case of skin contact If battery acid comes...

Page 127: ...through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If the battery is left in a discharg...

Page 128: ...at tery and to test the generator With this device you cannot overcharge the battery Switch off and disconnect the charger after charging Guideline Charge the battery regularly when the motorcycle is...

Page 129: ...guard p 96 100583 10 Pull starter relay off of the holder and remove protective cover 100584 10 990 Adventure Remove the faulty main fuse Info A defective fuse can be identified by the burned out fuse...

Page 130: ...e fuse in the starter relay so that it is available if needed Install the right underride guard p 96 Set the clock p 29 13 5 Changing the ABS fuses 990 Adventure Warning Fire hazard The electrical sys...

Page 131: ...1109125 p 191 Check whether the ABS warning lamp is still lit Mount the protective cover Tip Place the spare fuse in the storage compartment so that it is available if needed 100586 10 Changing the fu...

Page 132: ...ox Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses Use only fuses with the prescribed amperage Never by pass or repair fuses Info The fuse box containing the...

Page 133: ...e POWER RELAY 10 A ignition EFI control unit Fuse ACC1 CLOCK 10 A combination instrument socket supplementary devices permanent positive alarm system optional Fuse ACC2 10 A supplementary equipment ac...

Page 134: ...91 Fuse 58011109115 p 191 Info Spare fuses are located next to the fuse box Tip Replace the spare fuse in the fuse box so that it is available if needed Check that the power consumers are functioning...

Page 135: ...10 Unhook the headlight mask from the cockpit holder and remove it toward the front 100591 10 Disconnect plug in connector Place the headlight mask down on a soft cloth to prevent the headlight and t...

Page 136: ...headlight mask Install the front side cover p 80 Check the headlight setting p 140 13 9 Changing the low beam bulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to...

Page 137: ...nfo 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 with the headlight p 134 13 10 Changing the high beam...

Page 138: ...fo The bulb must be correctly seated at projections Connect the plug in connector and mount the rubber cap Install the headlight mask with the headlight p 134 13 11 Changing the parking light bulb in...

Page 139: ...ance 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 100597 10 Remove the screw on the rear of the turn si...

Page 140: ...ockwise until it engages in the thread Tighten the screw slightly 13 13 Changing the tail light bulb Note Damage to reflector Reduced luminance Grease on the lamp will evaporate due to the heat and be...

Page 141: ...unction Position the tail light Mount and tighten the nuts with the washers Guideline Nut tail light M6 8 Nm 5 9 lbf ft 13 14 Changing the brake light bulb Note Damage to reflector Reduced luminance G...

Page 142: ...n Position the tail light Mount and tighten nuts with the washers Guideline Nut tail light M6 8 Nm 5 9 lbf ft 13 15 Checking the headlight setting 0 0 A A 0 0 B B 400609 10 Park the vehicle on a horiz...

Page 143: ...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 13 17 Activating deactivating...

Page 144: ...up Switch off the ignition by turning the orange programming key to the OFF position Pull out the programming key Insert the black ignition key in the ignition lock Switch on the ignition by turning...

Page 145: ...y Turn the emergency OFF switch to the position 400919 10 Insert the orange programming key in the ignition lock Switch on the ignition by turning the orange programming key to the ON position FI Warn...

Page 146: ...itch off the ignition by turning the orange programming key to the OFF position Pull out the programming key Insert the black ignition key in the ignition lock Switch on the ignition by turning the bl...

Page 147: ...mber of flashes equals the number of functional black ignition keys includ ing the orange programming key Switch off the ignition by turning the orange programming key to the OFF position Pull out the...

Page 148: ...ature without causing any malfunctions 125 C 257 F 0 0 2 2 0 0 3 3 400619 10 Cooling takes place by means of the air stream and a radiator fan which is controlled by a thermoswitch The lower the speed...

Page 149: ...r 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 poi...

Page 150: ...coolant level in the compensating tank The coolant level must be between MIN and MAX If there is no coolant in the compensating tank Check the cooling system for leaks x Info Do not start up the motor...

Page 151: ...st be completely filled If the coolant level does not meet specifications Coolant loss 0 50 l 0 53 qt Check the cooling system for leaks x Info Do not start up the motorcycle Correct the coolant level...

Page 152: ...cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it...

Page 153: ...ew with a new seal ring and tighten it Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft 14 4 Filling bleeding the cooling system x Warning Danger of poisoning Coolant is poisonous and a health haz...

Page 154: ...ove 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 that all o...

Page 155: ...ean the vehicle on the side stand Check the coolant level in the compensating tank p 154 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or d...

Page 156: ...diator 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 pois...

Page 157: ...mpensating tank Check the cooling system for leaks x Info Do not start up the motorcycle Fill bleed the cooling system x p 151 If the coolant in the compensating tank is not at the required level but...

Page 158: ...lay in the throttle cable x p 157 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is...

Page 159: ...nector 100554 10 Plug in connector is located under the seat close to where the top of the shock absorber is attached By disconnecting the plug in connector the ignition curve for fuel with an octane...

Page 160: ...below 95 ROZ 95 RON 95 PON 91 for no more than one tank full The ignition curve must be adjusted to low octane fuel Disconnect plug in connector Figure 100554 10 p 157 Plug in connector disconnected...

Page 161: ...ne in an enclosed space without an effective exhaust extraction system Start the engine and run it until it reaches operating temperature Six bars of the temperature display light up 100622 10 Switch...

Page 162: ...creens x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse immediately with lu...

Page 163: ...rews and cover Pull oil screen out of the engine case with pliers 100625 10 Remove screw on the right fuel tank and remove screws Take off bracket 100626 10 Raise the vehicle off of the center stand p...

Page 164: ...ean all sealing surfaces 100628 10 Check seal ring of the oil sieve for damage and correct seating Insert oil sieve into the oil tank Position the oil line Mount and tighten the screws Guideline Remai...

Page 165: ...Mount and tighten the screws Guideline Screw clutch cover M6 10 Nm 7 4 lbf ft 100625 10 Position bracket Mount and tighten screws Guideline Remaining chassis screws M8 25 Nm 18 4 lbf ft Mount and tigh...

Page 166: ...ed of as stipulated in applicable regulations Condition The underride guard has been removed Place a suitable container under the engine 100632 10 Remove screws Take off oil filter cover with the O ri...

Page 167: ...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 Externa...

Page 168: ...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 the t...

Page 169: ...hen 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 204 Condition External temperature 0 C 32 F E...

Page 170: ...id etc should be disposed of as stipulated in applicable regulations Info If you clean the motorcycle regularly its value and appearance are maintained over a long period Avoid direct sunshine on the...

Page 171: ...casionally Info The heat produced causes water at inaccessible positions in the engine and on the brakes to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean...

Page 172: ...water Warm water would enhance the corrosive effects of salt 401060 01 Clean the motorcycle p 168 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with a wax ba...

Page 173: ...as empty as possible so that you can fill up with fresh fuel when you put the motorcycle back into operation Clean the motorcycle p 168 Change the engine oil and filter clean the oil screens x p 160...

Page 174: ...t warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 18 2 Preparing for use after storage 401059 01 Raise the vehicle off of the center...

Page 175: ...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 176: ...the coolant x p 150 Fill bleed the cooling system x p 151 Buckled or damaged radiator hose Change the radiator hose x Fuse FAN blown Change the fuses in the fuse box p 130 Thermostat defective Check t...

Page 177: ...hange the fuses in the fuse box p 130 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 130 Battery discharged I...

Page 178: ...trol unit Blink 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 Blink...

Page 179: ...indicator lamp flashes 3x short 1 second pause 1x short Error level condition Malfunction encryption query from EFI control unit to immobilizer control unit Blink code of immobilizer indica tor lamp 3...

Page 180: ...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 181: ...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 182: ...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 183: ...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 184: ...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 185: ...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 186: ...e clearance Exhaust at 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 all...

Page 187: ...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 22 1 Capacity engine oil...

Page 188: ...10 Nm 7 4 lbf ft Screw in alternator cover M6 10 Nm 7 4 lbf ft Screw bearing bolt in alternator cover M6 10 Nm 7 4 lbf ft Loctite 243 Screw camshaft bearing support M6 10 Nm 7 4 lbf ft Screw clutch c...

Page 189: ...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 190: ...12 Nm 8 9 lbf ft Plus cylinder head 2nd cylinder M12x1 5 25 Nm 18 4 lbf ft Plug oil filter housing M14x1 5 15 Nm 11 1 lbf ft Loctite 243 Bleeder flange alternator cover M16x1 5 10 Nm 7 4 lbf ft Locti...

Page 191: ...TECHNICAL DATA ENGINE TIGHTENING TORQUES 189 Nut primary gear M33LHx1 5 130 Nm 95 9 lbf ft Loctite 243...

Page 192: ...in Suspension travel 990 Adventure R Rear 245 mm 9 65 in Brake system Front Double disk brake with floating brake calipers and brake discs Rear Single disc brake with floating brake caliper and brake...

Page 193: ...ded 990 Adventure R 905 mm 35 63 in Ground clearance unloaded 990 Adventure 261 mm 10 28 in Ground clearance unloaded 990 Adventure R 301 mm 11 85 in Weight without fuel approx 990 Adventure 209 kg 46...

Page 194: ...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 195: ...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 196: ...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 197: ...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 198: ...TA FORK 196 Medium standard 4 8 N mm 27 4 lb in Hard 5 0 N mm 28 6 lb in Fork length 915 mm 36 02 in Air chamber length 100 30 20 mm 3 94 1 18 0 79 in Fork oil per fork leg 660 ml 22 31 fl oz Fork oil...

Page 199: ...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 200: ...5 in Shock absorber oil p 205 SAE 2 5 26 2 990 Adventure R Shock absorber part number 12 18 7K 09 Shock absorber WP Suspension PDS 5018 DCC PA Compression damping low speed Comfort 25 clicks Standard...

Page 201: ...omfort 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 225 mm 8 86 in Gas pres...

Page 202: ...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 203: ...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 204: ...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 205: ...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 206: ...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 209 SAE p 209 SAE 5W 40 Guideline Use o...

Page 207: ...ic fluid 15 According to ISO VG 15 Guideline Use only hydraulic oil that complies with the specified standard see specifications on the container and that possesses the corre sponding properties KTM r...

Page 208: ...SUBSTANCES 206 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91...

Page 209: ...or road use Guideline KTM recommends Motorex products Supplier Motorex Chainlube Road Cleaning and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Supplier...

Page 210: ...recommends Motorex products Supplier Motorex Bike Grease 2000 Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Universal oil spray Guideline KTM recommends...

Page 211: ...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 212: ...hanging 139 Brake linings front brake checking 104 rear brake checking 108 Brakes 56 Braking 56 C Center stand 43 Chain checking 92 checking for dirt 87 cleaning 87 Chain tension adjusting 90 checking...

Page 213: ...FF switch 23 Engine running in 46 Engine number 17 Engine oil adding 167 changing 160 draining 160 refilling 165 Engine oil level checking 159 Engine sprocket checking 92 Environment 10 F Filler caps...

Page 214: ...eadlight flasher switch 20 Headlight mask with headlight installing 134 removing 132 High beam bulb changing 135 Horn button 21 I Ignition curve adjusting to fuel quality 158 plug in connector 157 Ign...

Page 215: ...82 removing 81 Rear hub rubber dampers checking 117 Rear sprocket checking 92 Rear wheel installing 115 removing 113 Riding 52 starting off 52 S Seat mounting 83 removing 82 Seat lock 37 Service 8 Se...

Page 216: ...193 chassis tightening torques 200 202 engine 184 185 engine tightening torques 186 189 fork 194 196 shock absorber 197 199 Tire air pressure checking 119 Tire condition checking 118 Tool set 44 Trans...

Page 217: ...INDEX 215 View of vehicle front left side 12 rear right side 14 W Warning of slippery roads 33 Warranty 8 Work rules 9...

Page 218: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 09 2010 Photo Mitterbauer 3211657en 3211657en...

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