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BRAKE SYSTEM

M00662-10

–

Check the brake linings for minimum thickness



Minimum thickness



≥

1 mm (

≥

0.04 in)

» If the minimum thickness is less than specified:

–

Change the front brake linings.

–

Check the brake linings for damage and cracking.
» If there is damage or cracking:

–

Change the front brake linings.

12.7

Checking the free travel of foot brake lever

Warning

Danger of accidents

Brake system failure.

–

If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to over-
heating. Adjust the free travel on foot brake lever according to specifications.

C00316-10

–

Disconnect spring



–

Move the foot brake lever back and forth between the end stop and the contact to the
foot brake cylinder piston and check free travel



Guideline

Free travel at foot brake lever

3… 5 mm (0.12… 0.2 in)

» If the free travel does not equal the specification:

–

Adjust the basic position of the foot brake lever.

(

p. 88)

–

Attach spring



Содержание 690 DUKE R EU

Страница 1: ...OWNER S MANUAL 2015 690 Duke US Art no 3213273en...

Страница 2: ......

Страница 3: ...completely All specifications are non binding KTM Motorrad AG specifically reserves the right to modify or delete technical specifications prices col ors forms materials services designs equipment et...

Страница 4: ...1 According to the international quality management standard ISO 9001 KTM uses quality assurance processes that lead to the maximum possible quality of the products Issued by T V Management Service KT...

Страница 5: ...3 6 Customer service 19 4 VIEW OF VEHICLE 20 4 1 View of vehicle front left side 20 4 2 View of vehicle rear right side 22 5 SERIAL NUMBERS 24 5 1 Chassis number 24 5 2 Type label 24 5 3 Key number 2...

Страница 6: ...61 9 SERVICE SCHEDULE 63 9 1 Service schedule 63 10 TUNING THE CHASSIS 65 10 1 Adjusting the spring preload of the shock absorber 65 10 2 Adjusting the footrests 65 11 SERVICE WORK ON THE CHASSIS 68...

Страница 7: ...umers 112 14 7 Removing the headlight mask with the headlight 115 14 8 Refitting the headlight mask with the headlight 116 14 9 Changing the headlight bulb 117 14 10 Changing the parking light bulb 11...

Страница 8: ...g torques 155 22 3 Capacities 158 22 3 1 Engine oil 158 22 3 2 Coolant 159 22 3 3 Fuel 159 22 4 Chassis 159 22 5 Electrical system 161 22 6 Tires 161 22 7 Fork 161 22 8 Shock absorber 162 22 9 Chassis...

Страница 9: ...standing In the interest of your own safety have these jobs performed by an authorized KTM workshop There your motorcycle will be optimally cared for by specially trained experts using the specialist...

Страница 10: ...he homologated version 2 2 Safety advice A number of safety instructions need to be followed to operate the vehicle safely Therefore read this manual carefully The safety instruc tions are highlighted...

Страница 11: ...measures are not taken Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken Note Indicates a danger that will lead to considerable mac...

Страница 12: ...2 SAFETY ADVICE 10 2 4 Overview of labels M00693 10...

Страница 13: ...ype label Canada 2 Information chain tension 3 Information emission control 4 Information putting into operation 5 Information noise emission 6 Type label USA M00687 01 Type label Canada 700207 01 Inf...

Страница 14: ...2 SAFETY ADVICE 12 M00688 01 Information emission control 700210 01 Information putting into operation...

Страница 15: ...ould immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying KTM North America Inc If NHTSA receives multiple similar complaints it may open an investigati...

Страница 16: ...mer Support 1119 Milan Ave Amherst OH 44001 USA Phone 440 985 3553 www ktmusa com KTM Canada Inc Customer Support 1375 1 Marie Victorin Saint Bruno QC J3V 6B7 Phone 450 441 4451 x 4250 www ktmcanada c...

Страница 17: ...moval or puncturing of the main silencer baffles header pipes or any other components which conduct exhaust gases 2 Removal or puncturing of parts of the intake system 3 Lack of proper maintenance 4 R...

Страница 18: ...sk Wear protective clothing helmet boots gloves pants and jacket with protectors every time you ride the vehicle Always wear protective clothing that is in good condition and meets the legal requireme...

Страница 19: ...l of an end of life motorcycle Your authorized KTM dealer will be glad to advise you 2 14 Owner s Manual It is important that you read this Owner s Manual carefully and completely before making your f...

Страница 20: ...auxiliary substances such as fuel and lubricants as specified in the Owner s Manual 3 3 Spare parts accessories For your own safety only use spare parts and accessory products that are approved and or...

Страница 21: ...erve these exactly you will ensure a much longer service life for your motorcycle 3 5 Figures The figures contained in the manual may depict special equipment In the interest of clarity some component...

Страница 22: ...4 VIEW OF VEHICLE 20 4 1 View of vehicle front left side M00691 10...

Страница 23: ...4 VIEW OF VEHICLE 21 1 Clutch lever p 28 2 Seat 3 Passenger seat 4 Handrails p 44 5 Seat lock p 43 6 Engine number p 26 7 Shift lever p 45 8 Side stand p 46...

Страница 24: ...4 VIEW OF VEHICLE 22 4 2 View of vehicle rear right side M00692 10...

Страница 25: ...switch p 30 2 Turn signal switch p 31 2 Horn button p 29 3 Filler cap 4 Ignition steering lock p 32 5 Emergency OFF switch p 31 5 Electric starter button p 32 6 Hand brake lever p 28 7 Chassis number...

Страница 26: ...SERIAL NUMBERS 24 5 1 Chassis number 402324 10 The chassis number is stamped on the right side of the steering head 5 2 Type label 402294 10 The type label USA is located on the right side of the fram...

Страница 27: ...81 11 The type label Canada is located on the left side of the frame 5 3 Key number 402241 10 The key number can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the...

Страница 28: ...26 5 4 Engine number 401949 10 The engine number is located on the left side of the engine under the engine sprocket 5 5 Fork part number 402295 10 The fork part number is stamped on the inner side o...

Страница 29: ...5 SERIAL NUMBERS 27 5 6 Shock absorber part number 402382 10 Shock absorber article number is located on the left side of the shock absorber...

Страница 30: ...ver is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 6 2 Hand brake lever 602570 10 The hand brake lever is fitted on the right side of the handlebar...

Страница 31: ...rottle grip is fitted on the right side of the handlebar 6 4 Horn button M00655 10 The horn button is fitted on the left side of the handlebar Possible states Horn button in neutral position Horn butt...

Страница 32: ...l light are switched on High beam on Light switch is turned upwards In this position the high beam and the tail light are switched on 6 6 Headlight flasher switch M00656 12 The headlight flasher switc...

Страница 33: ...o the right The turn sig nal switch returns to the center position after activation To switch off the turn signal press the turn signal switch towards the switch housing 6 8 Emergency OFF switch 60255...

Страница 34: ...ing lock B00925 01 The ignition steering lock is located in front of the upper triple clamp Possible states Ignition off In this position the ignition circuit is interrupted a running engine stops and...

Страница 35: ...uttons p 33 Tachometer p 34 Indicator lights p 34 Display p 35 6 11 2 Function buttons 401426 10 You can change the display mode with the MODE button Possible display modes are the odometer ODO trip m...

Страница 36: ...he motorcy cle Possible states The turn signal indicator light flashes green simultaneously with the turn signal The turn signal is switched on The idling speed indicator lamp lights up green The tran...

Страница 37: ...as detected an emission or safety critical error The battery warning lamp lights up red The voltage in the vehicle system is too low ABS warning lamp lights up flashes yellow Status or error messages...

Страница 38: ...e of the 17 front wheel with a series pro duction tire The display then changes to the last selected mode 6 11 6 Speed display 401443 10 The speed is shown in kilometers per hour km h or in miles per...

Страница 39: ...ton 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 6 11 8 Time 401443 11 The time is shown in area of the disp...

Страница 40: ...n and the SET button pressed simultaneously The time is set 6 11 10 ODO display 401444 01 In the ODO display mode the total distance traveled is shown in kilometers or miles Info This value is retaine...

Страница 41: ...IP 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 999...

Страница 42: ...mark the display automatically changes to TRIP F and starts to count from 0 0 regardless of the previous display mode Info The low fuel warning lamp lights up in parallel to the TRIP F display 6 11 1...

Страница 43: ...always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately The fuel in the fuel tank expands when warm and may emerge if...

Страница 44: ...tion keys must be replaced Turn the ignition key 90 clockwise Open the filler cap 6 13 Closing the filler cap M00658 01 Fold down the filler cap Turn the ignition key 90 clockwise Push down the fille...

Страница 45: ...NTROLS 43 6 14 Seat lock B00928 10 The seat lock is located on the left side of the vehicle It can be locked with the ignition key 6 15 Tool set B00929 10 The tool set is located under the passenger s...

Страница 46: ...have a passenger the passenger can hold on the handrails during the journey 6 17 Passenger footrests B00931 01 The passenger footrests can be folded up and down Possible states Passenger footrests fol...

Страница 47: ...5 6 18 Shift lever 401950 10 The shift lever is mounted on the left side of the engine 401950 11 The gear positions can be seen in the photograph The neutral or idle position is between the first and...

Страница 48: ...cle The side stand is used for parking the motorcycle Info The side stand must be folded up during motorcycle use The side stand is coupled with the safety starting system see the riding instruc tions...

Страница 49: ...crashing 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...

Страница 50: ...your first trip read the entire operating instructions carefully Get to know the controls Adjust the basic position of the clutch lever p 79 Adjust the basic position of the hand brake lever p 82 Adj...

Страница 51: ...handling 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 mp...

Страница 52: ...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 distribu tion betwe...

Страница 53: ...vel p 89 Check the front brake linings p 86 Check the rear brake linings p 91 Check the brake system function Check the coolant level in the compensating tank p 125 Check the chain for dirt p 71 Check...

Страница 54: ...engines have a negative effect on the service life of the engine Always warm up the engine at low engine speeds B00782 10 Turn the emergency OFF switch to the position Switch on the ignition by turni...

Страница 55: ...equipped with a safety starting system You can only start the engine if the transmission is in neutral or if the clutch lever is pulled when a gear is engaged If the side stand is folded out and you s...

Страница 56: ...lock up 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 traffi...

Страница 57: ...the tires have been run in Warning Danger of accidents Unstable handling characteristics Do not exceed the maximum permitted weight and axle loads The overall weight consists of motorcycle operational...

Страница 58: ...release the clutch lever 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...

Страница 59: ...the brakes Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system Clean or dry a dirty or wet brake system by riding and braking gently Warning Danger of accidents R...

Страница 60: ...arning Danger of accidents Locking of the wheels due to braking action of the engine Pull the clutch during emergency braking full brake application and when braking on a slippery surface When braking...

Страница 61: ...ot components such as exhaust system radiator engine shock absorber and the brake system Allow these components to cool down before starting work on them Note Danger of damage The parked vehicle may r...

Страница 62: ...nd forward with your foot as far as it will go and lean the vehicle on it Lock the steering by turning the handlebar fully to the left pressing down the ignition key to the position and turning it to...

Страница 63: ...the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If con...

Страница 64: ...off the engine Open the filler cap p 41 Fill the fuel tank with fuel up to the lower edge of the filler neck Total fuel tank capacity approx 14 l 3 7 US gal Super unleaded ROZ 95 RON 95 PON 91 p 168 C...

Страница 65: ...heck the rear brake linings p 91 Check the brake discs p 83 Check the brake lines for damage and leakage Check the rear brake fluid level p 89 Check the free travel of the foot brake lever p 87 Check...

Страница 66: ...ange the air filter Clean the air filter box Check the fuel pressure Check the CO adjustment with the KTM diagnostics tool Check rectify the fluid level of the hydraulic clutch p 80 Check the screws a...

Страница 67: ...the spring process on the shock absorber The best spring preload setting is achieved when it is set for the weight of the rider and that of any baggage and a passenger thus ensuring an ideal compromis...

Страница 68: ...THE CHASSIS 66 C00329 10 Remove lock ring Remove the pin of the rider footrest Take off the rider footrest with the spring C00330 10 Remove screws C00331 01 Adjust the footrest bracket to the desired...

Страница 69: ...G THE CHASSIS 67 C00330 10 Mount and tighten screws Guideline Screw front footrest bracket M8 25 Nm 18 4 lbf ft Loctite 243 C00332 01 Mount the rider footrest with the spring and pin C00329 10 Mount l...

Страница 70: ...1 Mount the support of the wheel stand Insert the adapter in the rear wheel stand Adapter 61029055120 Rear wheel stand 61029055400 Stand the motorcycle upright align the lifting gear with the swingarm...

Страница 71: ...d Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Preparatory work Raise the motorcycle with the rear wheel stand p 68 602543 01...

Страница 72: ...l away or fall over Always place the vehicle on a firm and even surface Secure the motorcycle against falling over Remove the front wheel stand 11 5 Removing the passenger seat B00928 10 Insert the ig...

Страница 73: ...r seat until it clicks into place Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly After mounting the passenger seat check that it is loc...

Страница 74: ...nd grease and clean them with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be dispo...

Страница 75: ...procket rear sprocket bearings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to...

Страница 76: ...chain upwards near the vertical rib of the swingarm and measure the chain tension Info The upper chain section must be taut Chain wear is not always even Repeat this measurement at different chain pos...

Страница 77: ...bearings in the transmission and in the rear wheel will be under additional load In addition to premature wear this can cause the chain or the countershaft of the transmission to break in extreme case...

Страница 78: ...the markings on the left and right chain adjusters are in the same position relative to reference marks The rear wheel is then correctly aligned Info The upper part of the chain must be taut Chain we...

Страница 79: ...ain rear sprocket and engine sprocket 100132 10 Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the power set Info The engine sprocket rea...

Страница 80: ...in section Info Chain wear is not always even Repeat this measurement at different chain posi tions Maximum distance at the longest chain section 272 mm 10 71 in If the distance is greater than the sp...

Страница 81: ...rd M6 10 Nm 7 4 lbf ft Loctite 243 11 12 Adjusting the basic position of the clutch lever Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar Tu...

Страница 82: ...luid B00944 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Check the fluid level Fluid level below container rim 4 mm 0 1...

Страница 83: ...e been approved and or recommended by KTM Service work and repairs must be performed properly Your authorized KTM workshop will be glad to help The ABS is a safety system that prevents locking of the...

Страница 84: ...ar wheels differ greatly under extreme riding conditions for example when making wheelies or if the rear wheel spins This causes the ABS to switch off To reenable the ABS the vehicle must be stopped a...

Страница 85: ...ar brake discs in several places to ensure that it conforms to measurement Info Wear reduces the thickness of the brake disc at the contact surface of the brake disc Brake discs wear limit Front 4 2 m...

Страница 86: ...k the brake system and do not continue riding Your autho rized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of...

Страница 87: ...ke fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change...

Страница 88: ...ighten the screws Info Clean up overflowed or spilt brake fluid immediately with water 12 6 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake...

Страница 89: ...rake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to over heating Adjust the free travel on foot brake lev...

Страница 90: ...move screw Loosen nut and turn it back with ball joint until the maximum amount of free travel is reached To adjust the basic position of the foot brake lever to individual requirements loosen nut and...

Страница 91: ...n the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency...

Страница 92: ...h the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front an...

Страница 93: ...immediately with water 12 11 Checking the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized K...

Страница 94: ...linings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings Check the brake linings for damage and cracking If there is w...

Страница 95: ...on the brake disc Pull the brake caliper carefully back from the brake disc and hang it to one side Info Do not pull the hand brake lever while the brake caliper is removed 602546 10 Loosen screw by s...

Страница 96: ...the wheel bearing for damage and wear If the wheel bearing is damaged or worn Replace the wheel bearing Clean grease and mount the left and right spacers and the shaft seal rings Long life grease p 1...

Страница 97: ...n contact with the brake disc and there is a pressure point Fix the hand brake lever in the activated posi tion The brake calipers straighten Tighten screws Guideline Screw front brake caliper M10x1 2...

Страница 98: ...y work Raise the motorcycle with the rear wheel stand p 68 M00665 10 Main work Remove screw and pull wheel speed sensor out of the hole Remove nut Remove chain adjuster M00666 10 Withdraw wheel spindl...

Страница 99: ...rake discs Always lay down the wheel in such a way that the brake discs are not dam aged Take the rear wheel out of the swingarm Info Do not operate the foot brake lever when the rear wheel is removed...

Страница 100: ...earing is damaged or worn Replace the wheel bearing Remove bushing Clean and grease the mating surfaces of the bushings and the shaft seal rings Long life grease p 169 Install the bushing Clean and gr...

Страница 101: ...correctly on the adjusting screws 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...

Страница 102: ...the rear wheel p 96 602568 10 Main work Check bearing If the bearing is damaged or worn Replace the bearings Check rubber dampers of the rear hub for damage and wear If the rubber dampers of the rear...

Страница 103: ...erent 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 over the vehicle Warning Danger of acciden...

Страница 104: ...Info Note local national regulations concerning the minimum tread depth Minimum tread depth 2 mm 0 08 in If the tread depth is less than the minimum permissible depth Change the tires Check the age of...

Страница 105: ...omfort and maximum tire service life 400695 01 Remove the protection cap Check the tire pressure when the tires are cold Tire air pressure solo Front 2 0 bar 29 psi Rear 2 0 bar 29 psi Tire air pressu...

Страница 106: ...ttery acid and battery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets...

Страница 107: ...ry up and out of the battery holder 14 2 Installing the battery M00671 10 Main work Position the battery in the battery holder Battery CBTX9 BS p 160 The battery terminals face in the direction of tra...

Страница 108: ...ith battery acid and battery gases Keep sparks and open flames away from the battery Only charge in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid...

Страница 109: ...fe If the charging current charging voltage or charging time is exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the ve...

Страница 110: ...ry and to test the alternator With this device you cannot overcharge the battery Info Never remove lid Switch off the battery charger after charging and disconnect from the battery Guideline The charg...

Страница 111: ...re used Use only fuses with the prescribed amperage Never bypass or repair fuses Info The main fuse protects all power consumers of the vehicle The main fuse is under the passenger seat Preparatory wo...

Страница 112: ...burned out fuse wire A reserve fuse is located in the starter relay Install a new main fuse Fuse 58011109130 p 160 Tip Insert a new replacement fuse into the starter relay to have it available when n...

Страница 113: ...located under the passenger seat These fuses protect the return pump and the hydraulic unit of the ABS The third fuse which protects the ABS control unit is located in the fuse box Preparatory work S...

Страница 114: ...t the protection cover Finishing work Mount the passenger seat p 71 14 6 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is locate...

Страница 115: ...it Fuse 3 10 A fuel pump Fuse 4 10 A radiator fan Fuse 5 10 A horn brake light turn signal alarm system optional Fuse 6 15 A high beam low beam parking light tail light license plate lamp Fuse 7 10 A...

Страница 116: ...s or repair fuses Use spare fuses with the correct rating only Fuse 75011088010 p 160 Fuse 75011088015 p 160 Tip Replace the spare fuse in the fuse box so that it is available if needed Check that the...

Страница 117: ...e headlight mask with the headlight Preparatory work Switch off all power consumers and switch off the engine M00677 10 Main work Remove screws 602578 11 Fold the headlight mask forward Disconnect plu...

Страница 118: ...Main work Connect plug in connectors M00677 11 Position the headlight mask Mount and tighten screws Guideline Screw headlight EJOT 2 Nm 1 5 lbf ft Remaining screws chassis M5 5 Nm 3 7 lbf ft Check tha...

Страница 119: ...e lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off all power consumers and switch off the eng...

Страница 120: ...ition the new bulb in the headlight housing Headlight H4 socket P43t p 161 Tabs engage in the recesses Attach retaining clamp B00973 10 Mount protection cap Plug in connector Finishing work Refit the...

Страница 121: ...h off all power consumers and switch off the engine Remove the headlight mask with the headlight p 115 B00975 10 Main work Pull cable sleeve and the socket of parking light carefully out of the housin...

Страница 122: ...al glass Press the bulb carefully into the socket turn it counterclockwise by about 30 and pull it out of the socket Info Do not touch the reflector with your fingers and keep it free from grease Pres...

Страница 123: ...e in front of the wall and switch on the low beam Guideline Distance 5 m 16 ft The rider with luggage and passenger if applicable now mounts the motorcycle Check the headlight setting The light dark b...

Страница 124: ...e with rider and with luggage and a passenger if applicable the light dark boundary must be exactly on the lower mark applied in Checking the headlight setting Info Turn counterclockwise to increase t...

Страница 125: ...re without causing any malfunctions 125 C 257 F 100167 10 Cooling takes place by means of the air stream and a radiator fan which is controlled by a thermoswitch The lower the speed the less the cooli...

Страница 126: ...reach of children Condition The engine is cold Preparatory work Stand the motorcycle upright on a horizontal surface M00680 10 Main work Remove radiator cap and plug from the compensating tank Check...

Страница 127: ...oss Coolant p 166 If you had to add more coolant than the specified amount 0 50 l 0 53 qt Fill bleed the cooling system p 128 Mount radiator cap 15 3 Checking the coolant level in the compensating tan...

Страница 128: ...ant out of reach of children Condition The engine is cold The radiator is completely full Preparatory work Park the motorcycle on a horizontal surface M00681 10 Main work Check the coolant level in th...

Страница 129: ...not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water immedi ately and contact a physician Immediately clean contaminated areas on the skin with soap a...

Страница 130: ...ap and water If coolant is swallowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children M00682 10 Remove radiator cap B00985 10 Rem...

Страница 131: ...nt 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 the 5th bar of the temperature indicator lights...

Страница 132: ...sired number is aligned with marking Set the Map Select switch to Soft Set the adjusting wheel to position 1 Soft Homologated performance with very gentle response Set the Map Select switch to Advance...

Страница 133: ...riding position and determine distance between the upper edge of your boot and the shift lever Distance between shift lever and upper edge of boot 10 20 mm 0 39 0 79 in If the distance does not meet...

Страница 134: ...ever on the shift shaft in the required position and engage the gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle components during the...

Страница 135: ...etween the lower and upper edge of the oil level viewer If the engine oil level is not at the specified level Add the engine oil p 138 17 2 Changing the engine oil and filter cleaning the oil screens...

Страница 136: ...container under the engine Remove the oil drain plug with the magnet and seal ring Completely drain the engine oil Thoroughly clean the oil drain plug with a magnet B00988 10 Remove screws Remove the...

Страница 137: ...rain the engine oil Thoroughly clean the parts and sealing area B00991 10 Insert the oil filter Oil the O rings of the oil filter covers Mount oil filter covers and Mount and tighten the screws Guidel...

Страница 138: ...aling area B01002 10 Position the oil screen with the O rings Mount and tighten screw plug with the O ring Guideline Plug oil screen M20x1 5 15 Nm 11 1 lbf ft B00994 10 Position the oil screen with th...

Страница 139: ...oil SAE 10W 60 00062010035 p 166 Alternative engine oil Engine oil SAE 10W 50 p 167 Install and tighten the oil filler plug with the O ring Danger Danger of poisoning Exhaust gases are toxic and inha...

Страница 140: ...performance of the engine oil do not mix different types of engine oil If appropriate change the engine oil Install and tighten the oil filler plug with the O ring Danger Danger of poisoning Exhaust...

Страница 141: ...leaners brake fluid etc should be disposed of as stipulated in applicable regulations Info If you clean the motorcycle regularly its value and appearance will be maintained over a long period Avoid di...

Страница 142: ...d on the brake system to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Clean the chain p 72 Treat bare metal parts except for brake discs and exhaust system wit...

Страница 143: ...Clean the motorcycle p 139 Clean the brake system Info After EVERY trip on salted roads thoroughly wash the brake calipers and brake linings with cold water and dry carefully This should be done after...

Страница 144: ...ueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 169 Refuel p 61 Clean the motorcycle p 139 Change the engine oil and filter clean the oil screens...

Страница 145: ...ort time only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 19 2 Preparing for use after storage 401059 01...

Страница 146: ...r to neutral Engine turns but does not start Operating error Carry out the start procedure p 52 Fuse 3 blown Change the fuses of individual power consumers p 112 The plug in connection of the fuel hos...

Страница 147: ...ghts flashes Defect in fuel injection system Read out the fault memory using the KTM diag nostics tool N The idle indicator lamp does not light up when the transmission is in neutral Gear position sen...

Страница 148: ...brake light and horn are not functional Fuse 5 blown Change the fuses of individual power consumers p 112 Time is not correctly displayed Fuse 1 blown Change the fuses of individual power consumers p...

Страница 149: ...ning lamp MIL 12 FI warning lamp MIL flashes 1x long 2x short Error level condition Engine coolant temperature sensor input signal too low Engine coolant temperature sensor input signal too high Blink...

Страница 150: ...Error level condition Lambda sensor cylinder 1 sensor 1 circuit fault Blink code of FI warning lamp MIL 22 FI warning lamp MIL flashes 2x long 2x short Error level condition Gear position sensor circ...

Страница 151: ...ult Blink code of FI warning lamp MIL 37 FI warning lamp MIL flashes 3x long 7x short Error level condition Ignition coil 1 cylinder 1 circuit fault Blink code of FI warning lamp MIL 39 FI warning lam...

Страница 152: ...sor heater cylinder 1 sensor 1 input signal too high Blink code of FI warning lamp MIL 65 FI warning lamp MIL flashes 6x long 5x short Error level condition E PROM error Blink code of FI warning lamp...

Страница 153: ...l too low Accelerator position sensor circuit A input signal too high Blink code of FI warning lamp MIL 86 FI warning lamp MIL flashes 8x long 6x short Error level condition Accelerator position senso...

Страница 154: ...INACTIVE DBW internal power relay active Blink code of FI warning lamp MIL 92 FI warning lamp MIL flashes 9x long 2x short Error level condition DBW throttle actuator control IC stuck open Blink code...

Страница 155: ...es 9x long 5x short Error level condition DBW stop function system error stop function B system error Blink code of FI warning lamp MIL 96 FI warning lamp MIL flashes 9x long 6x short Error level cond...

Страница 156: ...ld 0 07 0 13 mm 0 0028 0 0051 in Crankshaft bearing 2 roller bearings Conrod bearing Needle bearing Piston pin bearing Piston pin with DLC coating Pistons Forged light alloy Piston rings 1 L ring 1 ta...

Страница 157: ...ed 1 550 1 650 rpm Starting aid Electric starter automatic decompressor 22 2 Engine tightening torques Screw membrane fixation M3 2 Nm 1 5 lbf ft Loctite 243 Hose clamp intake flange M4 2 5 Nm 1 84 lb...

Страница 158: ...octite 243 Screw axial lock of camshaft M6 10 Nm 7 4 lbf ft Loctite 243 Screw clutch cover M6 10 Nm 7 4 lbf ft Screw clutch slave cylinder M6x20 10 Nm 7 4 lbf ft Loctite 243 Screw clutch slave cylinde...

Страница 159: ...lbf ft Loctite 243 Screw plug crankshaft clamp M8 20 Nm 14 8 lbf ft Stud exhaust flange M8 10 Nm 7 4 lbf ft Loctite 243 Cylinder head screw M10 Tightening sequence Tighten diagonally beginning with th...

Страница 160: ...e 243 Engine case stud M16x1 5 25 Nm 18 4 lbf ft Loctite 243 Rotor nut M18x1 5 100 Nm 73 8 lbf ft Nut engine sprocket M20x1 5 80 Nm 59 lbf ft Loctite 243 Nut inner clutch hub M20x1 5 100 Nm 73 8 lbf f...

Страница 161: ...der coated Fork WP Suspension Up Side Down 4357 Shock absorber WP Suspension emulsion with Pro Lever linkage Suspension travel Front 135 mm 5 31 in Rear 135 mm 5 31 in Brake system Front Disc brake wi...

Страница 162: ...m 57 72 0 59 in Seat height unloaded 835 mm 32 87 in Ground clearance unloaded 192 mm 7 56 in Weight without fuel approx 149 5 kg 329 6 lb Maximum permissible front axle load 150 kg 331 lb Maximum per...

Страница 163: ...W Brake tail light LED License plate lamp LED 22 6 Tires Front tires Rear tires 120 70 ZR 17 M C 58W TL Metzeler SPORTEC M7 RR 160 60 ZR 17 M C 69W TL Metzeler SPORTEC M7 RR Additional information is...

Страница 164: ...torques Screw combination instrument EJOT 1 Nm 0 7 lbf ft Screw headlight EJOT 2 Nm 1 5 lbf ft Screw headlight mask EJOT 1 Nm 0 7 lbf ft Screw side stand switch M4 2 Nm 1 5 lbf ft Loctite 243 Remainin...

Страница 165: ...m 1 5 lbf ft Screw brake fluid reservoir of rear brake M6 5 Nm 3 7 lbf ft Screw chain sliding guard M6 10 Nm 7 4 lbf ft Loctite 243 Screw control unit holder M6 3 Nm 2 2 lbf ft Screw exhaust pipe clam...

Страница 166: ...dlebar clamp M8 20 Nm 14 8 lbf ft Screw handrail M8x30 Countersunk screw 18 Nm 13 3 lbf ft Loctite 243 Screw handrail cover M8x20 18 Nm 13 3 lbf ft Loctite 243 Screw ignition lock tamper proof screw M...

Страница 167: ...lbf ft Loctite 243 Screw front brake caliper M10x1 25 45 Nm 33 2 lbf ft Loctite 243 Screw top shock absorber M10x1 25 50 Nm 36 9 lbf ft Loctite 243 Lambda sensor M12x1 25 25 Nm 18 4 lbf ft Nut frame t...

Страница 168: ...UID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Only use high quality coolant with corrosion inhibitor for aluminum motors even in countries with high temperatures Using inferior antifre...

Страница 169: ...fication JASO T903 MA p 171 SAE p 171 SAE 10W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properti...

Страница 170: ...g properties Recommended supplier Motorex Hydraulic Fluid 75 Super unleaded ROZ 95 RON 95 PON 91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that mat...

Страница 171: ...Chain Clean Chain lube for road use Guideline Recommended supplier Motorex Chainlube Road Fuel additive Recommended supplier Motorex Fuel Stabilizer Long life grease Recommended supplier Motorex Bike...

Страница 172: ...ex Moto Polish Shine Preserving materials for paints metal and rubber Recommended supplier Motorex Moto Protect Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommend...

Страница 173: ...vice intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines In most motorcycles the gearbox and the clutch are lubricated wit...

Страница 174: ...ke linings front brake checking 86 rear brake checking 91 Brake system 81 92 Brakes 57 Brakes applying 57 C Capacity coolant 159 engine oil 137 158 fuel 62 159 Chain checking 77 cleaning 72 dirt check...

Страница 175: ...ctric starter button 32 Emergency OFF switch 31 Engine running in 48 Engine characteristics setting 130 Engine number 26 Engine oil adding 138 changing 133 Engine oil level checking 133 Engine sprocke...

Страница 176: ...ndicator lamps 34 Intended use 8 K Key number 25 L Light switch 30 Loading the vehicle 49 M Main fuse changing 109 Motorcycle cleaning 139 raising with the front wheel stand 69 raising with the rear w...

Страница 177: ...lever 45 basic position adjusting 131 basic position checking 131 Shifting 54 Shock absorber spring preload adjusting 65 Shock absorber part number 27 Side stand 46 Spare parts 18 Starting 52 Steerin...

Страница 178: ...signal bulb changing 120 Turn signal switch 31 Type label 24 U Use definition 8 V View of vehicle left front side 20 rear right side 22 W Warranty 18 Winter operation checks and maintenance steps 141...

Страница 179: ...3213273en 3213273en 10 2014 KTM Motorrad AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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