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KTM Chassis 690 SMC, Owner'S Manual, Page: 126 / 186

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KTM Chassis 690 SMC Owner'S Manual Download Page 126

MAINTENANCE WORK ON CHASSIS AND ENGINE

124

100285-10

–

Remove screws

. Remove filter box top

.

100286-10

Note

Engine failure

 

Unfiltered intake air has a negative effect on the service life of the

engine.

–

Never ride the vehicle without an air filter since dust and dirt can get into the
engine and result in increased wear.

–

Remove air filter

.

Summary of Contents for Chassis 690 SMC

Page 1: ...OWNER S MANUAL 2009 690 SMC EU 690 SMC AUS UK ART NO 3211365en...

Page 2: ......

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

Page 4: ...only with the express written permission of the copyright owner ISO 9001 12 100 6061 According to the international quality management standard ISO 9001 KTM uses quality assurance processes that lead...

Page 5: ...Combination instrument display 25 Combination instrument speedometer 26 Setting kilometers or miles 26 Combination instrument time 27 Setting the clock 27 Combination instrument display ODO 28 Combina...

Page 6: ...e fork legs 66 Cleaning the dust boots of the fork legs 67 Removing the fork protector 68 Installing the fork protector 69 Checking play of steering head bearing x 69 Adjusting play of steering head b...

Page 7: ...ing system x 131 Adjusting basic position of clutch lever 133 Checking rectifying the fluid level of the hydraulic clutch 133 Checking play in gas Bowden cable 134 Adjusting the play in the gas Bowden...

Page 8: ...CONTENTS 6 AUXILIARY SUBSTANCES 176 STANDARDS 178 INDEX 179...

Page 9: ...hnical understanding In the interest of your own safety have these jobs done in an authorized KTM workshop There your motorcycle will be serviced optimally by specially trained experts using the speci...

Page 10: ...t roads can lead to above average wear of components such as the transmission train or the brakes For this reason it may be necessary to service or replace worn parts before the limit specified in the...

Page 11: ...mply with the manufacturer s specific advice on its usage Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear Change damaged or worn parts Fo...

Page 12: ...you can ensure that such problems and conflicts do not have to occur To protect the future of motorcycle sport make sure that you use your motorcycle legally display environmental consciousness and r...

Page 13: ...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 It is important that you read this o...

Page 14: ...VIEW OF VEHICLE 12 3 1 View of vehicle front left side 600637 10...

Page 15: ...VIEW OF VEHICLE 13 1 Hand brake lever 2 Clutch lever 3 Seat 4 Filler cap 5 Handrail 6 Front brake caliper 7 Shift lever 8 Engine number 9 Side stand 10 Footrest 11 Seat release strap...

Page 16: ...VIEW OF VEHICLE 14 3 2 View of vehicle rear right 600638 10...

Page 17: ...er switch horn button 3 Rear mirror 4 Combination instrument 5 Emergency OFF switch electric starter button 6 Throttle grip 7 Chassis number 8 Brake caliper rear 9 Passenger footrest 10 Shock absorber...

Page 18: ...N OF SERIAL NUMBERS 16 4 1 Chassis number 100217 10 The chassis number is stamped on the steering head on the right 4 2 Type label 100218 10 Type label is located on the upper right frame tube below t...

Page 19: ...10 The key 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 4 4 Engine number 600479 10 The engine number is stamped on th...

Page 20: ...NUMBERS 18 4 5 Fork part number 600480 10 The fork part number is stamped on the inner side of the fork stub 4 6 Shock absorber part number 100216 10 The shock absorber part number is on the right of...

Page 21: ...lever is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 5 2 Hand brake lever 600598 11 The hand break lever is fitted on the right side of the handle...

Page 22: ...e tail light are switched on 5 4 Flasher switch 100223 10 The flasher switch is fitted on the left side of the handlebar Possible states Flasher light off Flasher light left on Flasher switch pressed...

Page 23: ...perated in this position 5 6 Emergency OFF switch 100225 10 The emergency OFF switch is fitted on the left side of the handlebar Possible states Emergency OFF switch off In this position the ignition...

Page 24: ...steering lock 600825 01 The ignition steering lock is located in front of the seat Possible states Ignition OFF In this position the ignition circuit is interrupted a running engine stops and a non r...

Page 25: ...ion buttons Tachometer Indicator lights Display 5 10 Combination instrument function buttons 700117 01 You can change the display mode with the MODE button Possible display modes are distance traveled...

Page 26: ...t the operating state of the motorcy cle Possible states The flasher indicator lamp flashes green simultaneously with the flashers Flasher light is switched on The idle speed indicator lamp lights up...

Page 27: ...mbination instrument display 700118 01 When you switch on the ignition all display segments light up for a second as a function test 700119 01 LEnGth Following the display function test the wheel circ...

Page 28: ...e speed is shown in kilometers per hour km h or in miles per hour mph 5 15 Setting kilometers or miles Info If you change the unit the value ODO is retained and converted accordingly Making the settin...

Page 29: ...tton pressed until the display mode changes from km h to mph or from mph to km h Guideline Activation duration of MODE button 10 s 5 16 Combination instrument time 700115 01 The time is shown in area...

Page 30: ...on pressed simultaneously The time is set 5 18 Combination instrument display ODO 700120 01 In the ODO display mode the total distance traveled is shown in kilometers or miles Info This value is retai...

Page 31: ...ng TRIP 2 Info The TRIP 2 trip counter is always running and counts up to 999 9 The trip counter can be used to measure the distance covered during trips or between two refueling stops After the value...

Page 32: ...F display the fuel warning light switches on 5 22 Combination instrument coolant temperature indicator 700124 01 The temperature display consists of 12 bars The more bars showing the hotter the coolan...

Page 33: ...sert the ignition key Turn the ignition key 90 counterclockwise and remove the filler cap Info The filler cap has a tank air vent system 5 24 Closing filler cap 100228 01 Put the filler cap back on an...

Page 34: ...rails 100229 10 The handrails are used for moving the motorcycle around When you have a passenger the passenger can hold on the handrails during the journey 5 26 Seat release 100230 10 The seat can be...

Page 35: ...ootrests can be folded up and down Possible states Passenger footrests folded up For operation without a passenger Passenger footrests folded down For operation with a passenger 5 28 Shift lever 60048...

Page 36: ...ns can be seen in the photograph The neutral or idle position is between the first and second gears 5 29 Foot brake pedal 600485 10 The footbrake pedal is located in front of the right footrest The fo...

Page 37: ...c starter system see the riding instruc tions Possible states Side stand folded out The vehicle can be supported on the side stand The safety electric starter system is active Side stand folded in Thi...

Page 38: ...ront and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle Warning Danger of accidents Uncontrollable handling characteristics due to non ap...

Page 39: ...just the basic position of handbrake lever p 80 Adjust the basic position of the footbrake lever x p 89 Get used to handling the vehicle on a car park before making a longer trip Try also to ride as s...

Page 40: ...ing characteristics at high speed Adapt your speed according to your payload Ride more slowly if your motorcycle is loaded with cases or other baggage Maximum speed with baggage 130 km h 80 8 mph Warn...

Page 41: ...h a way that it cannot be burned or singed by the hot exhaust system If you carry any baggage make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dist...

Page 42: ...1 000 km 621 4 mi Check the chain tension p 74 Clean the chain p 73 Check the tire condition p 103 Checking the tire air pressure p 105 Check the front brake fluid level p 81 Check the rear brake flu...

Page 43: ...closed space without an effective exhaust extraction system Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery electronic components and safety equip...

Page 44: ...tion test of the combination instrument is finished When starting DO NOT open the throttle If you open the throttle during the start ing procedure fuel is not injected by the engine management system...

Page 45: ...ck Warning Danger of accidents Malfunctions caused by incorrect ignition key position Do not change the ignition key position during a journey Warning Danger of accidents Distraction from traffic acti...

Page 46: ...s been run in Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational and with a full tank...

Page 47: ...lease the clutch and open the throttle Info You can see the positions of the 6 forward gears in the figure The neutral or idle position is between the first and second gears First gear is used for sta...

Page 48: ...ely When you shift to neutral the FI warning lamp MIL starts to flash Info From the flashing rhythm you can derive a two digit number the so called flashing code The flashing code tells you which comp...

Page 49: ...t the brake discs must first be cleaned by brak ing To brake release the throttle and operate the front and rear brakes simultaneously On sandy wet or slippery surfaces use the rear brake Braking shou...

Page 50: ...erial damage Damage and destruction of components by excessive load The side stand is designed for the weight of the motorcycle only Do not sit on the motorcycle when it is supported by the side stand...

Page 51: ...m and can escape if the tank is overfilled See specifications on filling up with fuel Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clo...

Page 52: ...al fuel tank capacity approx 12 l 3 2 US gal Super unleaded ROZ 95 RON 95 PON 91 p 175 Close the filler cap p 31 100240 10 Press the SET button for two seconds The fuel level warning lamp switches off...

Page 53: ...ect fit ting and leaks x Clean check and grease the O ring of the fuel hose connection x Check the cable harness of the throttle valve body for damage and cor rect positioning x Attachments Check the...

Page 54: ...90 Change brake fluid x Check brake lines for damage and leakage Check the free play of the foot brake lever p 89 Check braking Check screws and guide bolts of brake system for tightness x Chassis Che...

Page 55: ...000 km 621 4 mi K50A every 5 000 km 3 107 mi after every race K100A every 10 000 km 6 214 mi J1A annually J2A every 2 years 8 2 Important maintenance work to be carried out by an authorized KTM works...

Page 56: ...SERVICE SCHEDULE 54 J2A every 2 years...

Page 57: ...andlebar to the straight ahead position Align the work stand to the front with the adapters to the fork legs Work stand front 61029055300 Info Always jack up the rear of the motorcycle first Jack up t...

Page 58: ...d screw it into the link forks Work stand adapter 61029055110 Work stand rear 61029055100 Stand the motorcycle upright align the work stand to the rear and jack up the motorcy cle 9 4 Taking the rear...

Page 59: ...derstood as a guideline and should always be the basis of your own personal chassis adaptation Do not change the adjustments at random or by more than 40 since otherwise the riding characteristics cou...

Page 60: ...s Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping 9 7 Adjusting the rebound damping of the fork Info The hydraulic rebound damping det...

Page 61: ...sion damping in low and high speed range separately Dual Compression Control The term low speed and high speed refer to the movement of the shock absorber during compression and not the riding speed o...

Page 62: ...e with a screwdriver as far as the last perceptible click Info Do not loosen nut Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Compression dampi...

Page 63: ...orber Danger Danger of accidents The shock absorber is under high pressure The shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any mainte na...

Page 64: ...ession damping high speed Comfort 1 5 turns Standard 1 turn Sport 0 5 turn Full payload 0 5 turn Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping 9 11 Adjusti...

Page 65: ...licks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping 9 12 Measuring the unloaded rear wheel sag Ja...

Page 66: ...to help you by holding the motorcycle upright Measure the distance between the rear axle and the fixed point again Make a note of the value as measurement Info The static sag is the difference between...

Page 67: ...son now has to measure the distance between the rear axle and a fixed point Make a note of the value as measurement Info The riding sag is the difference between measurements and Check the riding sag...

Page 68: ...r clean it thoroughly 700541 01 Loosen locking ring Turn adjusting ring until the spring is no longer under tension Hook wrench T106S Measure the overall spring length when not under tension Tension t...

Page 69: ...ork legs Jack up the motorcycle and secure it against falling over The front wheel is no longer in contact with the ground and the fork legs are no longer under tension Remove the fork protector p 68...

Page 70: ...and oil the dust boots and inner fork tube of both fork legs Universal oil spray p 177 Press the dust boots back into their normal position Remove excess oil Install the fork protector p 69 Remove th...

Page 71: ...ine Remaining screws chassis M6 10 Nm 7 4 lbf ft 9 20 Checking play of steering head bearing x Warning Danger of accidents Unsafe riding behavior due to incorrect steering head bearing play The steeri...

Page 72: ...the entire steering range No resting locations should be noticeable If click positions are noticeable Adjust play of the steering head bearing x p 70 Check the steering head bearing and change if nec...

Page 73: ...the motorcycle from the work stand 9 22 Handlebar position 0 0 B B 0 0 A A 400271 11 On the upper triple clamp there are 2 holes at a distance to each other Distance between holes 15 mm 0 59 in The ho...

Page 74: ...the cables and lines Remove the two screws Remove the handlebar support Place the handlebar support in the required position Fit and tighten the two screws Guideline Screw handlebar support M10 40 Nm...

Page 75: ...Reduced braking 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 Warning Environmental hazard Problem materia...

Page 76: ...of the secondary power train chain engine 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...

Page 77: ...ot meet specifications Adjust the chain tension p 75 9 27 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the componen...

Page 78: ...ve to the 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 should check this setting at different chain positions...

Page 79: ...ar sprocket engine sprocket are worn Replace rear sprocket engine sprocket Info The engine sprocket rear sprocket and chain should always be replaced together For safety reasons the chain has no chain...

Page 80: ...uld repeat this measurement at differ ent chain positions Maximum distance at the longest sec tion of the chain 272 mm 10 71 in If distance is greater than the specified measurement Have the chain cha...

Page 81: ...d tighten screws and Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Condition Number of teeth 45 teeth Insert nut in hole Position the chain guide Mount and tighten screws and Guideline Remain...

Page 82: ...177 in If the brake disc thickness is less than the specified value Replace the brake disc Check the front and rear brake discs for damage cracks and deformation If damage cracks or deformation are v...

Page 83: ...id Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop 600603 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal position C...

Page 84: ...ording to the service plan in an authorized KTM workshop Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid ba...

Page 85: ...spilt brake fluid immediately with water 9 35 Checking the front brake linings Warning Danger of accidents Reduced braking due to worn brake linings Worn brake linings should be replaced immediately...

Page 86: ...system maintained and repaired in an authorized KTM workshop Warning Skin irritations Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of chi...

Page 87: ...alid Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Never user...

Page 88: ...ighten the screws Info Clean up overflowed or spilt brake fluid immediately with water 9 37 Removing front brake linings x Warning Danger of accidents Improper brake maintenance and repair Always have...

Page 89: ...of accidents Reduced braking due to use of non approved brake linings Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construction and fr...

Page 90: ...and install bolts Info The spring hanger of the springs must be positioned facing upwards Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a tight sp...

Page 91: ...piston and check free travel Guideline Free play at foot brake lever 3 5 mm 0 12 0 2 in Info You will know that contact has been made with the foot brake cylinder piston when there is increased resis...

Page 92: ...cylinder so that the foot brake pedal has the necessary free travel Hold screws in place and tighten the nuts Guideline Nut foot brake cylinder screw M6 10 Nm 7 4 lbf ft Check the free play of the fo...

Page 93: ...rear brake fluid x p 91 9 42 Adding rear brake fluid x Warning Danger of accidents Brake system failure If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system o...

Page 94: ...teries etc according to regulations Info Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact...

Page 95: ...s grind on the brake disc The braking effect is greatly reduced and the brake discs are destroyed 100260 10 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum...

Page 96: ...linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construction and friction factor of the brake linings and therefore the brake power can differ...

Page 97: ...uid escapes from the brake fluid reservoir If it does clean it up Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes 100288 10 Remove the safe...

Page 98: ...screw cap with the membrane Info Clean up overflowed or spilt brake fluid immediately with water 9 45 Removing front wheel x Jack up the rear of the motorcycle p 56 Jack up the front of the motorcycl...

Page 99: ...to damaged brake discs Always lay the wheel down in such a way that the brake disc is not damaged Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork 600626 11 Rem...

Page 100: ...ase p 177 Lift the front wheel into the fork position it and insert the wheel spindle Mount and tighten screw Guideline Screw front wheel spindle M24x1 5 40 Nm 29 5 lbf ft Position the brake caliper a...

Page 101: ...push down hard on the fork several times to align the fork legs Fully tighten screws Guideline Screw fork stub M8 15 Nm 11 1 lbf ft Taking rear from work stand p 56 9 47 Removing rear wheel x Jack up...

Page 102: ...f the swing arm Info Do not operate the foot brake when the rear wheel is removed 9 48 Installing the rear wheel x Warning Danger of accidents Reduced braking due to oil or grease on the brake discs A...

Page 103: ...ontact 100270 10 Push the rear wheel forward as far as possible and lay the chain on the rear sprocket Mount the wheel spindle chain adjusters and nuts Guideline In order that the rear wheel is correc...

Page 104: ...e rubber dampers of the rear hub for damage and wear If the rubber dampers of the rear hub are damaged or worn Change all rubber dampers in the rear hub 600624 10 Lay the read wheel on a workbench wit...

Page 105: ...handling characteristics due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Warning Danger of accidents Re...

Page 106: ...of the tires Info The tire s date of the manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking The first two digits refer to the week of manufac...

Page 107: ...spoke tension tap each spoke with a screwdriver Guideline You should hear a high note Spoke nipple front wheel M4 5 4 Nm 3 lbf ft Spoke nipple rear wheel M5 4 Nm 3 lbf ft Info If you hear different t...

Page 108: ...t 2 0 bar 29 psi Rear 2 0 bar 29 psi Tire air pressure with passenger fully loaded Front 2 0 bar 29 psi Rear 2 2 bar 32 psi If the tire pressure does not meet specifications Correct tire pressure Moun...

Page 109: ...the battery x Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contac...

Page 110: ...battery rack Info Never operate the motorcycle with a discharged battery or without a battery In both cases electrical components and safety devices can be damaged The vehi cle is therefore no longer...

Page 111: ...in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Warning Enviro...

Page 112: ...ent the charge voltage and the charge time are exceeded electrolyte escapes through the breathing holes The battery capacity is then reduced If the battery is discharged from starting it must be recha...

Page 113: ...ever remove lid Charge the battery with a maximum of 10 of the capacity specified on the bat tery housing Switch off and disconnect the charger after charging Guideline The charge current charge volta...

Page 114: ...ne Remove the seat p 106 600604 10 Remove protection covers 600605 10 Use a needle nose plier to remove a defective main fuse Insert the new main fuse Fuse 58011109130 p 164 Info If the new fuse burns...

Page 115: ...Changing the fuses of power consumers Info The fuse box containing the fuses of the individual power consumers is located under the seat Switch off all power consumers and switch off the engine Remov...

Page 116: ...ntrol unit Fuse 4 10A fuel pump Fuse 5 10A radiator fan Fuse 6 10A horn brake light flasher light alarm system optional Fuse 7 15A high beam low beam parking light tail light license plate lamp Fuse 8...

Page 117: ...are fuse of the right rating Fuse 75011088010 p 164 Fuse 75011088015 p 164 Info If the new fuse burns out contact an authorized KTM workshop Tip Put a new spare fuse in the fuse box for future use if...

Page 118: ...nced Set the adjusting wheel to position 2 Advanced homologated performance with extremely direct responsiveness Set the Map Select switch to Standard Set the adjusting wheel to position 3 4 5 6 7 8 o...

Page 119: ...off all power consumers and switch off the engine 100296 11 Cover the fender with a cloth to protect it from damage Remove the screws on the left and right Tip the headlight mask forward and pull it...

Page 120: ...the headlight mask with the headlight 100294 11 Connect the connectors of headlight and flasher lights Check lighting function 100295 10 Remove the cloth from the fender attach the headlight mask to...

Page 121: ...ideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 9 63 Changing the headlight bulb Note Damage to reflector Keep the glass of the bulb free of grease Clean the glass bulb with a clean cloth before...

Page 122: ...headlight bulb in the headlight using the spring bar Replace the rubber cap Attach the connector Install the headlight mask with the headlight p 118 9 64 Changing the parking light bulb Note Damage t...

Page 123: ...he bulb socket Parking light W2 1x9 5d p 164 Insert the bulb socket in the reflector Insert the rubber cap Install the headlight mask with the headlight p 118 9 65 Changing the flasher bulb Note Damag...

Page 124: ...t and turn it clockwise until it stops Flasher light BAU15s p 164 Position the diffuser Insert the screw and turn it counterclockwise first until it engages in the thread Tighten the screw slightly Ch...

Page 125: ...ing the headlight range Check the headlamp setting p 122 800084 10 Turn adjusting screw to adjust the headlight range Guideline For a motorcycle with rider the light dark boundary must be exactly on t...

Page 126: ...Remove filter box top 100286 10 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never ride the vehicle without an air filter since dust and dirt can...

Page 127: ...flush against the air filter box along the entire sealing sur face If the air filter is not correctly mounted dust and dirt can penetrate into the engine and can cause damage Hook filter box top into...

Page 128: ...permissible without danger of function prob lems 125 C 257 F 400407 10 The coolant is cooled by the air stream and a radiator fan which is controlled by a ther moswitch The lower the speed the less th...

Page 129: ...ts out of the reach of children 100283 10 Condition Engine is cold Stand the motorcycle on its side stand on a horizontal surface Remove the cap of the compensating tank Check antifreeze of coolant 25...

Page 130: ...not meet specifications Correct the coolant level and find out the cause of the loss Alternative 1 Coolant p 172 Alternative 2 Coolant mixed ready to use p 172 Refit the radiator cap 9 72 Checking th...

Page 131: ...is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolants out of the reach of children 100283 10 Condition Engine is cold Stand the motorcycle o...

Page 132: ...gets very hot and is under pressure Do not open the radiator the radiator hoses or other components of the cooling system when the engine is hot Allow the engine and radiator to cool down If you are s...

Page 133: ...ling system x Warning Danger of poisoning Coolants are poisonous and a health hazard Avoid contact between coolants and skin eyes and clothing If fuel gets into your eyes rinse immediately with water...

Page 134: ...ger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the...

Page 135: ...hand only and do not apply any force Do not make any adjustments while riding 100282 10 Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw When adjusting the cl...

Page 136: ...the hydraulic clutch Hydraulic fluid 15 p 174 Position the cover with the membrane Mount and tighten the screws 9 77 Checking play in gas Bowden cable 400192 10 Move the handlebar to the straight ahe...

Page 137: ...et it run idle Move the handlebar to and fro over the entire steer ing range The idle speed must not change If the idle speed changes Adjust the play in the gas Bowden cable x p 135 9 78 Adjusting the...

Page 138: ...eck the engine oil level Info After switching off the engine wait for one minute and then check The engine oil must be between the lower and upper edge of the oil level viewer If the engine oil level...

Page 139: ...lf hold the affected area under cold water immediately Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batt...

Page 140: ...he oil filter x Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area u...

Page 141: ...O ring Pull oil filter out of the oil filter housing Circlip pliers reverse 51012011000 100203 10 Remove screws Remove oil filter with the O ring Pull oil filter out of the oil filter housing Circlip...

Page 142: ...Cleaning the oil screens x Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affe...

Page 143: ...e O rings 100206 10 Remove plug with oil screen and the O rings Completely drain the remaining engine oil Thoroughly clean the parts and sealing area 100207 10 Position oil screen with the O rings Mou...

Page 144: ...1 lbf ft 9 85 Filling up with engine oil x Info Too little engine oil or poor quality engine oil results in premature wear to the engine 100209 10 Remove filler plug with O ring from the clutch cover...

Page 145: ...gine and check that it is oil tight Check the engine oil level p 136 9 86 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the engine 100209 10 Remo...

Page 146: ...nd can result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in a closed space without an effective exhaust...

Page 147: ...onnection Engine turns only if the clutch lever is drawn The vehicle is in gear Shift gear to neutral The vehicle is in gear and the side stand is folded out Shift gear to neutral Defect in safety sta...

Page 148: ...se Have the radiator hose changed Thermostat defective Have thermostat checked Fuse 5 blown Change the fuses of power consumers p 113 Defect in radiator fan system Have the radiator fan system checked...

Page 149: ...d Fuse 2 blown Change the fuses of power consumers p 113 Set the clock p 27 Battery discharged Ignition not switched off when vehicle was parked Recharge the battery x p 109 Battery is not charged by...

Page 150: ...IL 08 FI warning lamp MIL flashes briefly 8x Possible cause Input signal from throttle grip sensor too low Input signal from throttle grip sensor too high Flashing code FI of warning lamp MIL 09 FI wa...

Page 151: ...g code FI of warning lamp MIL 15 FI warning lamp MIL flashes 1x long 5x short Possible cause Input signal from rollover sensor too low Input signal from rollover sensor too high Flashing code FI of wa...

Page 152: ...MIL flashes 3x long 3x short Possible cause Malfunction in injection valve circuit cylinder 1 Flashing code FI of warning lamp MIL 37 FI warning lamp MIL flashes 3x long 7x short Possible cause Malfu...

Page 153: ...warning lamp MIL 60 FI warning lamp MIL flashes 6x long Possible cause Malfunction in throttle stepper motor circuit Flashing code FI of warning lamp MIL 68 FI warning lamp MIL flashes 6x long 8x sho...

Page 154: ...FLASHING CODE 152 Flashing code FI of warning lamp MIL 92 FI warning lamp MIL flashes 9x long 2x short Possible cause Malfunction in voltage supply circuit of EPT control unit internal...

Page 155: ...gulations Info If you clean the motorcycle regularly its value and appearance are maintained over a long period Avoid direct sunshine on the motorcycle during cleaning Before you clean the motocycle s...

Page 156: ...covers on the handlebar instruments to allow water to evaporate After the motorcycle has cooled off oil or grease all moving parts and bearings Clean the chain p 73 Treat bare metal parts except for b...

Page 157: ...an it with cold water Warm water would reinforce the effect of the salt Clean the motorcycle p 153 Treat the engine the swingarm and all other bare or galvanized parts except brake discs with a wax ba...

Page 158: ...as possible so that you can fill up with fresh fuel when you put the motorcycle back into operation Clean the motorcycle p 153 Change the engine oil and filter clean the oil screens x p 136 Check the...

Page 159: ...Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 14 2 Putting into operation after storage Take the front fro...

Page 160: ...0 13 mm 0 0028 0 0051 in Crankshaft bearing 2 roller bearings Conrod bearing Needle bearing Piston pin bearing Bronze bush Pistons Forged light alloy Piston rings 1 L ring 1 tapered compression pisto...

Page 161: ...8AI 9 Spark plug electrode gap 0 9 mm 0 035 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid Electric starter automatic decompressor 15 1 Capacity engine oil Engin...

Page 162: ...il filter cover M5 6 Nm 4 4 lbf ft Screw oil pump cover M5 6 Nm 4 4 lbf ft Loctite 243 Plug vacuum connection M6 10 Nm 7 4 lbf ft Loctite 243 Screw Autodecompression M6 3 4 Nm 2 2 3 lbf ft Loctite 243...

Page 163: ...rail M6 10 Nm 7 4 lbf ft Loctite 243 Screw timing chain tensioning rail M6 10 Nm 7 4 lbf ft Loctite 243 Screw valve cover M6 10 Nm 7 4 lbf ft Screw water pump cover M6 10 Nm 7 4 lbf ft Screw water pu...

Page 164: ...net M12x1 5 20 Nm 14 8 lbf ft Oil pressure regulator valve plug M12x1 5 20 Nm 14 8 lbf ft Plug oil bore M14x1 5 15 Nm 11 1 lbf ft Loctite 243 Engine case stud M16x1 5 25 Nm 18 4 lbf ft Loctite 243 Rot...

Page 165: ...Front Disc brake with radially screwed four piston brake caliper floating brake disc Rear Disc brake with single piston brake caliper floating Brake discs diameter Front 320 mm 12 6 in Rear 240 mm 9...

Page 166: ...load 150 kg 331 lb Maximum permissible rear axle load 200 kg 441 lb Maximum permissible overall weight 350 kg 772 lb Battery YTZ10S Battery voltage 12 V Nominal capacity 8 6 Ah maintenance free Fuse 5...

Page 167: ...Pirelli Dragon Supercorsa Pro 160 60 ZR 17 M C 69W TL Pirelli Dragon Supercorsa Pro Additional information is available in the Service section under http www ktm com 17 2 Capacity fuel Total fuel tan...

Page 168: ...15 clicks Standard 10 clicks Sport 5 clicks Full payload 5 clicks Spring length with preload spacer s 480 mm 18 9 in Spring rate Weight of rider 65 75 kg 143 165 lb 5 0 N mm 28 6 lb in Weight of rider...

Page 169: ...speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload 18 mm 0 71...

Page 170: ...TECHNICAL DATA SHOCK ABSORBER 168 Riding sag 70 80 mm 2 76 3 15 in Fitted length 400 mm 15 75 in Shock absorber fluid Shock absorber oil SAE 2 5 50180342S1 p 174...

Page 171: ...3 Nm 2 2 lbf ft Screw starter cable on starter M5 3 Nm 2 2 lbf ft Spoke nipple rear wheel M5 4 Nm 3 lbf ft Nut foot brake cylinder screw M6 10 Nm 7 4 lbf ft Remaining nuts chassis M6 15 Nm 11 1 lbf f...

Page 172: ...er M8 25 Nm 18 4 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front footrest bracket M8 25 Nm 18 4 lbf ft Screw fuel tank bottom M8 20 Nm 14 8 lbf ft Screw handlebar clamp M8 20 Nm 14 8 lbf ft Lo...

Page 173: ...t Screw side stand M10 35 Nm 25 8 lbf ft Loctite 243 Screw top shock absorber M10 45 Nm 33 2 lbf ft Loctite 243 Screw front brake caliper M10x1 25 45 Nm 33 2 lbf ft Loctite 243 Lambda probe M12x1 25 2...

Page 174: ...torex products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant in countries with high temperatures also Use of low quality ant...

Page 175: ...e corresponding properties KTM recommends Motorex products Synthetic engine oil Supplier Motorex Motorex KTM Cross Power 4T Engine oil SAE 10W 50 According to JASO T903 MA p 178 SAE p 178 SAE 10W 50 G...

Page 176: ...c fluid 15 According to ISO VG 15 Guideline Use only hydraulic fluid that complies with the specified standards see specifications on the container and that possesses the corre sponding properties KTM...

Page 177: ...SUBSTANCES 175 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91...

Page 178: ...and polishing materials for metal rubber and plastic Specification KTM recommends Motorex products Supplier Motorex Protect Shine 645 Contact spray Specification KTM recommends Motorex products Suppli...

Page 179: ...2000 Motorcycle cleaner Specification KTM recommends Motorex products Supplier Motorex Moto Clean 900 Onroad chain spray Specification KTM recommends Motorex products Supplier Motorex Chain Lube 622...

Page 180: ...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 181: ...ging 84 87 front brake checking 83 rear brake changing 93 rear brake checking 93 Removing front brake linings 86 Brakes 46 Braking 46 C Chain checking for dirt 73 checking for wear 78 cleaning 73 Chai...

Page 182: ...lectric starter button 22 Emergency OFF switch 21 Engine running in 37 Engine characteristic adjusting 115 Engine number 17 Engine oil adding 143 changing 136 draining 137 refilling 142 Engine oil lev...

Page 183: ...eadlight mask with headlight installing 118 removing 117 Horn button 21 I Ignition lock 22 Indicator lights 24 K Key number 17 L Light switch 20 Loading the vehicle 38 M Main fuse changing 111 Mainten...

Page 184: ...oving 99 Refueling fuel 49 Riding 43 starting up 43 S Seat mounting 107 removing 106 Seat release 32 Service plan 51 54 Shift lever 33 Shifting 43 Shock absorber 57 compression damping general 59 comp...

Page 185: ...htening torques 169 171 engine 158 159 engine tightening torques 160 162 fork 166 shock absorber 167 168 Tire air pressure checking 105 Tire condition checking 103 Transport 9 Troubleshooting 145 147...

Page 186: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 11 2008 Photo Mitterbauer 3211365en 3211365en...

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