KTM 990 Adventure R USA 2010 Page 101 Owner'S Manual Download | Manualshive

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MAINTENANCE WORK ON FRAME AND ENGINE

99

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. (

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 R USA 2010

Page 1: ...OWNER S MANUAL 2010 990 Adventure USA 990 Adventure R USA Art no 3211515en...

Page 2: ......

Page 3: ...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 modify or...

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: ...tor lamps 35 Combination instrument display 36 Combination instrument speedometer 37 Setting kilometers or miles 37 Combination instrument time 38 Setting the clock 39 Combination instrument display O...

Page 6: ...r 81 Adjusting the high speed compression damping of the shock absorber 83 Adjusting the rebound damping of the shock absorber 84 Adjusting the spring preload of the shock absorber 86 Bleeding the for...

Page 7: ...g deactivating the ignition key 142 Removing the storage compartment and hanging it to one side x 145 Installing the storage compartment x 146 Removing the left fuel tank x 147 Installing the left fue...

Page 8: ...ine oil 192 Capacity coolant 192 TECHNICAL DATA ENGINE TIGHTENING TORQUES 193 TECHNICAL DATA CHASSIS 197 Lighting equipment 199 Tires 199 Capacity fuel 200 TECHNICAL DATA FORK 201 990 Adventure USA 20...

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: ...ful sport and we naturally hope that you can enjoy it to the full However it can also lead to problems with the environment and conflict with other persons Responsible behavior in handling the motorcy...

Page 13: ...IMPORTANT INFORMATION 11...

Page 14: ...IMPORTANT INFORMATION 12 Overview of labels 100643 10...

Page 15: ...mission control 3 USA type label 4 Information on the evaporative emission control system 5 Information on suspension tuning 6 Information on refueling 7 Information on chain tension 8 Canada type lab...

Page 16: ...IMPORTANT INFORMATION 14 B00108 01 Information on emission control 400635 01 USA type label...

Page 17: ...IMPORTANT INFORMATION 15 B00109 01 Information on the evaporative emission control system 100644 01 Information on suspension tuning...

Page 18: ...IMPORTANT INFORMATION 16 400630 01 Information on refueling 400628 01 Information on chain tension...

Page 19: ...IMPORTANT INFORMATION 17 400636 01 Canada type label B00110 01 Information on noise emission Notes warnings Pay close attention to the notes warnings...

Page 20: ...iate measures are not taken Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken Warning Identifies a danger that will lead to...

Page 21: ...arrants that this exhaust system at the time of sale meets all applicable U S EPA federal noise standards This warranty extends to the first person who buys this exhaust system for purposes other than...

Page 22: ...ould be checked for necessary repairs or replacement parts if motorcycle noise has increased significantly through use Otherwise the owner may become subject to penalties depending on local laws Consu...

Page 23: ...21...

Page 24: ...VIEW OF VEHICLE 22 View of vehicle front left side vehicle differs slightly from photo 100645 10...

Page 25: ...IEW OF VEHICLE 23 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 26: ...VIEW OF VEHICLE 24 View of vehicle rear right side vehicle differs slightly from photo 100646 10...

Page 27: ...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 28: ...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 Type label 100543 10 The type label is located on the right fram...

Page 29: ...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 30: ...MBERS 28 Fork part number 100545 10 The fork part number is stamped on the inner side of the fork stub Shock absorber part number 100546 10 The shock absorber part number is stamped on the upper part...

Page 31: ...er is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting Hand brake lever 100506 10 The hand brake lever is fitted on the right side of the handlebar The...

Page 32: ...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 Headlight flasher switch 100508 10 The headlight flasher switch is fi...

Page 33: ...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 34: ...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 Immobilizer 400915...

Page 35: ...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 36: ...ination 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 TRIP 2 and t...

Page 37: ...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 transm...

Page 38: ...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 USA The ABS warning lamp...

Page 39: ...21 front wheel with a series production tire The display then changes to the last selected mode Combination instrument speedometer 400838 10 The speed is shown in kilometers per hour km h or in miles...

Page 40: ...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 Combination instrument time 400893 11...

Page 41: ...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 42: ...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 43: ...de is active Keep the SET button pressed The TRIP 2 display is set to 0 0 Combination instrument TRIP F display 400842 01 If the fuel level drops to the reserve mark the display automatically changes...

Page 44: ...etting 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 until...

Page 45: ...isplay when the ambient temperature rises above the specified value again Temperature 4 C 39 F Combination instrument coolant temperature indicator 400617 01 The temperature display consists of 12 bar...

Page 46: ...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 deactivated wh...

Page 47: ...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 48: ...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 Unlocking the stor...

Page 49: ...Turn the ignition key to position Remove the ignition key Opening the storage compartment 100520 10 Unlock the storage compartment p 46 Press button toward the seat and raise the cover at the same ti...

Page 50: ...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 47 Handrails 100522 10 The handrails are used for moving...

Page 51: ...ation provided by the luggage manufacturer 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 dismantling th...

Page 52: ...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 Shift lever 100526 10 Shift lever is mounted on the left side...

Page 53: ...econd gears 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 sa...

Page 54: ...center stand in addition to a side stand Passenger footrests 100530 10 The passenger footrests can be folded up and down Possible states Passenger footrests folded up For operation without a passenge...

Page 55: ...CONTROLS 53 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 56: ...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 recommended...

Page 57: ...p 161 Adjust the free travel of hand brake lever p 99 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 al...

Page 58: ...dling 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 Wa...

Page 59: ...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 60: ...chain p 90 Check the tire condition p 117 Check the tire air pressure p 118 Check the front brake fluid level p 100 Check the rear brake fluid level p 104 Check the front brake linings p 103 Check th...

Page 61: ...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 safety...

Page 62: ...electric 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...

Page 63: ...slowly and simultaneously open the throttle carefully Shifting riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control Avoid abrupt load alterations and...

Page 64: ...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 optim...

Page 65: ...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 66: ...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 67: ...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 overall w...

Page 68: ...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 Braki...

Page 69: ...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 of...

Page 70: ...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 71: ...zard 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 immediately...

Page 72: ...5 3 US gal Super unleaded ROZ 95 RON 95 PON 91 p 213 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 73: ...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 74: ...ed and free of leaks Check the rear brake fluid level p 104 Check the free travel of the foot brake lever p 103 Check that the shock absorber and fork are leak tight Perform a fork service and shock a...

Page 75: ...nd correct routing x Check the antifreeze and coolant level p 152 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 76: ...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 77: ...hile 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 handwhe...

Page 78: ...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 79: ...ick Finally check that the seat is correctly mounted 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 payload I...

Page 80: ...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 fork ty...

Page 81: ...nd 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 adjustment...

Page 82: ...counterclockwise to reduce damping 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 b...

Page 83: ...hock 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 s...

Page 84: ...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 USA Compression damping low sp...

Page 85: ...arts 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 be...

Page 86: ...t 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping Adjusting the rebound damping of the shock abso...

Page 87: ...number of clicks corresponding to the shock absorber type Guideline 990 Adventure USA Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks 990 Adventure R USA R...

Page 88: ...ded 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 type a...

Page 89: ...reduce the spring preload Bleeding the fork legs Jack up the vehicle on the center stand p 75 100536 10 Remove bleeder screws briefly Any excess pressure escapes from the interior of the fork Mount a...

Page 90: ...e 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 oi...

Page 91: ...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 92: ...their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oi...

Page 93: ...ng 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 transmissio...

Page 94: ...Adjust the chain tension p 92 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 power tr...

Page 95: ...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 96: ...rocket 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 sp...

Page 97: ...ce 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...

Page 98: ...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 99: ...y 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 nor ma...

Page 100: ...ke 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 In...

Page 101: ...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 102: ...Do not make any adjustments while riding 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 a...

Page 103: ...m 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 contact...

Page 104: ...lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 100558 10 Move the brake f...

Page 105: ...red 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 thickn...

Page 106: ...e travel does not meet specifications Adjust the basic position of foot brake lever x Checking the rear brake fluid level Warning Danger of accidents Failure of the brake system If the brake fluid lev...

Page 107: ...rake 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 contact...

Page 108: ...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 109: ...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 Re...

Page 110: ...heck the brake linings for damage and cracking If there is wear or tearing Change the rear brake linings x Removing the front wheel x Jack up the vehicle on the center stand p 75 Bear down on the rear...

Page 111: ...e screw 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...

Page 112: ...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 bearin...

Page 113: ...Guideline Screw front wheel spindle M25x1 5 45 Nm 33 2 lbf ft Raise the vehicle off of the center stand p 76 Pull the front wheel brake and push down hard on the fork several times to align the fork...

Page 114: ...the rear wheel x Jack up the vehicle on the center stand p 75 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 USA Remove...

Page 115: ...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 116: ...eel always operate the foot brake until the pressure point is reached Check the rear hub rubber dampers x p 116 100571 10 Check the wheel bearing for damage and wear If the wheel bearing is damaged or...

Page 117: ...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 referenc...

Page 118: ...ubber 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 with t...

Page 119: ...haracteristic 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 road g...

Page 120: ...the 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 man...

Page 121: ...sure does not meet specifications Correct the tire pressure Mount the dust cap Checking spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that the spoke...

Page 122: ...e ter If spokes of the same length and diameter vibrate with a different tone this is an indication that the spoke tensions differ You should hear a high note If the spoke tension differs Correct the...

Page 123: ...tery 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 Keep...

Page 124: ...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 125: ...ttery 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 and...

Page 126: ...e with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Warning Environmental hazard Battery parts and acid are harmful to the envi...

Page 127: ...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 128: ...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 129: ...ving the right underride guard 100581 10 Remove screws Remove the right underride guard Installing the right underride guard 100581 11 Position right underride guard Mount and tighten screws Guideline...

Page 130: ...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 con...

Page 131: ...move 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 I...

Page 132: ...draulic 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 127 100585 10 Cha...

Page 133: ...ve cover Tip Place the spare fuse in the storage compartment so that it is available if needed Install the right underride guard p 127 Changing the fuses in the fuse box Warning Fire hazard The electr...

Page 134: ...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 inst...

Page 135: ...ABS Tip Replace the spare fuse in the fuse box so that it is available if needed 100637 10 990 Adventure R USA Use spare fuses with the correct rating only Fuse 58011109110 p 198 Fuse 58011109115 p 1...

Page 136: ...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 137: ...the turn signal cables and swing the side cover up toward the vehicle Mount and tighten screws with the washers Guideline Remaining chassis nuts M6 15 Nm 11 1 lbf ft Check the function of turn signal...

Page 138: ...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 134 Check the headlight setting p 141 Changing...

Page 139: ...ix it with the holding ring Low beam high beam H4 socket P43t p 199 Info The projections of the lamp must engage in the recess of the headlight housing Connect the connector and mount the rubber cap I...

Page 140: ...36 Changing the turn 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 greas...

Page 141: ...rew and first turn it counterclockwise until it engages in the thread Tighten the screw slightly Changing the tail light bulb Note Damage to reflector Reduced luminance Grease on the lamp will evapora...

Page 142: ...e 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 Changing the brake light bulb Note Damage to reflector Reduced lumin...

Page 143: ...ghting function Position the tail light Mount and tighten nuts with the washers Guideline Nut tail light M6 8 Nm 5 9 lbf ft Checking the headlight setting 0 A A 0 B B 400609 10 Park the vehicle on a h...

Page 144: ...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 Activating deactivat...

Page 145: ...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 146: ...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 147: ...te 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...

Page 148: ...he storage compartment and swing it to the right Place a cloth between the right fuel tank and the storage compartment to prevent damage Installing the storage compartment x 100616 10 Remove the cloth...

Page 149: ...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 immediate...

Page 150: ...level 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 th...

Page 151: ...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 152: ...ant temperature without causing any malfunctions 125 C 257 F 0 2 2 0 3 3 400619 10 Cooling takes place by means of the air stream and a radiator fan which is controlled by a thermoswitch The lower the...

Page 153: ...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 poisoning C...

Page 154: ...is 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 210 Alternative 2 Coolant mixed ready to use p 210 Mount...

Page 155: ...on The engine is cold Remove the front side cover p 134 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 156: ...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 157: ...ling 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 poisonou...

Page 158: ...ant Mount screw with a new seal ring and tighten it Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft Filling bleeding the cooling system x Warning Danger of poisoning Coolant is poisonous and a he...

Page 159: ...ightened Remove bleeder screw 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 160: ...iator cap Lean the vehicle on the side stand Check the coolant level in the compensating tank p 151 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousne...

Page 161: ...w 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...

Page 162: ...mount the nuts This ensures that all required parts are available when needed Installing the radiator guard 0 5 5 0 1 1 0 1 1 0 2 2 0 3 3 0 4 4 100639 10 Place nuts onto tabs of the radiator Hook radi...

Page 163: ...f adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding Checking rectifying the fluid level of the hydraulic clutch Info The f...

Page 164: ...oes not meet specifications Adjust the play in the throttle cable x p 163 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When runni...

Page 165: ...rottle cable 3 5 mm 0 12 0 2 in Tighten counter nut Checking the engine oil level Jack up the vehicle on the center stand p 75 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them...

Page 166: ...l Add engine oil p 172 Replace the oil dipstick Changing the engine oil and filter cleaning the oil screens x B00119 01 Drain engine oil clean oil screens x p 164 Install the oil filter x p 170 Instal...

Page 167: ...ated in applicable regulations Info Drain the engine oil only when the engine is warm Remove the underride guard x p 120 Remove the left fuel tank x p 147 100624 10 Place a suitable container under th...

Page 168: ...er stand p 76 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 169: ...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 170: ...ng 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 water W...

Page 171: ...69 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 172: ...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 External...

Page 173: ...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 174: ...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 211 Condition External temperature 0 C 32 F...

Page 175: ...5 or higher can be used 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 76 To activate the ignition cur...

Page 176: ...MAINTENANCE WORK ON FRAME AND ENGINE 174 Mount the seat p 77...

Page 177: ...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 178: ...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 179: ...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 180: ...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 181: ...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 182: ...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 183: ...ning lamp FI MIL flashes 5x long 3x short Error level condition Fuel evaporation valve short circuit to ground or open circuit Fuel evaporation valve input signal too high Flash code of warning lamp F...

Page 184: ...ld absolute pressure sensor cylinder 2 connection leaks Flash code of warning lamp FI MIL 81 Warning lamp FI MIL flashes 8x long 1x short Error level condition Immobilizer control unit malfunction in...

Page 185: ...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 186: ...e coolant x p 155 Fill bleed the cooling system x p 156 Buckled or damaged radiator hose Change the radiator hose x Fuse FAN blown Change the fuses in the fuse box p 131 Thermostat defective Check the...

Page 187: ...Change the fuses in the fuse box p 131 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 131 Battery discharged...

Page 188: ...fo 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 th...

Page 189: ...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 90 Treat bare metal parts except for...

Page 190: ...an it with cold water Warm water would enhance the corrosive effects of salt Clean the motorcycle p 186 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with a w...

Page 191: ...186 Change the engine oil and filter clean the oil screens x p 164 Check the antifreeze x Check the tire air pressure p 118 Remove the battery x p 121 Recharge the battery x p 124 Guideline Storage te...

Page 192: ...peration after storage Raise the vehicle off of the center stand p 76 Recharge the battery x p 124 Install the battery x p 123 Set the clock p 39 Refuel p 69 Carry out checks before putting into opera...

Page 193: ...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 194: ...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 Capacity engine oil Engine o...

Page 195: ...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 196: ...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 197: ...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 198: ...TECHNICAL DATA ENGINE TIGHTENING TORQUES 196 Nut primary gear M33LHx1 5 130 Nm 95 9 lbf ft Loctite 243...

Page 199: ...in Suspension travel 990 Adventure R USA 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...

Page 200: ...Adventure R USA 920 mm 36 22 in Ground clearance unloaded 990 Adventure USA 261 mm 10 28 in Ground clearance unloaded 990 Adventure R USA 316 mm 12 44 in Weight without fuel approx 990 Adventure USA 2...

Page 201: ...ight W5W socket W2 1x9 5d 12 V 5 W Brake light P21W socket BA15s 12 V 21 W License plate lamp W5W socket W2 1x9 5d 12 V 5 W Tires Front tire Rear tire Condition 90 90 21 M C 54V TL Pirelli SCORPION MT...

Page 202: ...TECHNICAL DATA CHASSIS 200 Capacity fuel Total fuel tank capacity approx 20 l 5 3 US gal Super unleaded ROZ 95 RON 95 PON 91 p 213 Fuel reserve approx 4 l 1 1 US gal...

Page 203: ...ll 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 pay...

Page 204: ...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 205: ...TA FORK 203 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 206: ...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 click...

Page 207: ...5 in Shock absorber oil p 212 SAE 2 5 990 Adventure R USA Shock absorber part number 12 18 7E 09 Shock absorber WP Suspension PDS 5018 DCC PA Compression damping low speed Comfort 25 clicks Standard 2...

Page 208: ...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 209: ...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 210: ...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 211: ...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 212: ...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 213: ...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 216 SAE p 216 SAE 5W 40 Guideline Use o...

Page 214: ...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 215: ...SUBSTANCES 213 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91...

Page 216: ...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 217: ...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 218: ...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 219: ...ke checking 100 rear brake checking 104 Brake light bulb changing 140 Brake linings front brake checking 103 rear brake checking 107 Brakes 65 Braking 65 C Center stand 52 Chain checking 94 checking f...

Page 220: ...ank checking 151 Cooling system 150 filling bleeding 156 D Display 36 E Electric starter button 33 Emergency OFF switch 33 Engine running in 55 Engine number 27 Engine oil adding 172 changing 164 drai...

Page 221: ...44 Headlight light range adjusting 142 Headlight adjustment checking 141 Headlight bulb changing 136 Headlight flasher switch 30 Headlight mask with headlight installing 136 removing 135 Horn button 3...

Page 222: ...R Radiator guard installing 160 removing 159 Rear hub rubber dampers checking 116 Rear sprocket checking 94 Rear wheel installing 114 removing 112 Riding 61 starting up 61 S Seat mounting 77 removing...

Page 223: ...hanging 139 Technical data chassis 197 200 chassis tightening torques 207 209 engine 191 192 engine tightening torques 193 196 fork 201 203 shock absorber 204 206 Tire air pressure checking 118 Tire c...

Page 224: ...INDEX 222 View of vehicle front left side 22 rear right side 24 W Warning of slippery roads 43 Warranty 8 Work rules 9...

Page 225: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 11 2009 Photo Mitterbauer 3211515en 3211515en...

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