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SERVICE WORK ON THE ENGINE

146

Danger

Danger of poisoning

Exhaust gases are toxic and inhaling them may 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 an enclosed space without an effective
exhaust extraction system.

–

Start the engine and check that it is oil-tight.

Finishing work

–

Check the engine oil level. (

p. 138)

Содержание 690 SMC AUS/UK

Страница 1: ...OWNER S MANUAL 2013 690 SMC R EU 690 SMC R AUS UK Art no 3211954en...

Страница 2: ......

Страница 3: ...specifications are non binding KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications prices colors forms materials services designs equipment etc without...

Страница 4: ...ccording 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 KTM S...

Страница 5: ...number 20 5 2 Type label 20 5 3 Key number 21 5 4 Engine number 21 5 5 Fork part number 22 5 6 Shock absorber part number 22 6 CONTROLS 23 6 1 Clutch lever 23 6 2 Hand brake lever 23 6 3 Throttle gri...

Страница 6: ...absorber 63 10 7 Adjusting the rebound damping of the shock absorber 64 10 8 Handlebar position 65 10 9 Adjusting the handlebar position x 66 11 SERVICE WORK ON THE CHASSIS 67 11 1 Raising the motorcy...

Страница 7: ...x 109 14 2 Installing the battery x 110 14 3 Recharging the battery x 111 14 4 Changing the main fuse 114 14 5 Changing fuses of individual power consumers 115 14 6 Removing the headlight mask with th...

Страница 8: ...ter operation 149 19 STORAGE 150 19 1 Storage 150 19 2 Preparing for use after storage 152 20 TROUBLESHOOTING 153 21 BLINK CODE 156 22 TECHNICAL DATA 160 22 1 engine 160 22 2 engine tightening torques...

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: ...n Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken 2 4 Tampering warning Tampering with the noise control system is prohibited Federal law p...

Страница 12: ...hem may 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 an enclosed space without an effective exh...

Страница 13: ...s In some instances a thread locker e g Loctite is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them for damage and...

Страница 14: ...hen will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury Keep the Owner s Manual in an accessible place to enable you to refer to it as...

Страница 15: ...accessory products that are approved and or recommended by KTM and have them installed by an authorized KTM workshop KTM accepts no liability for other products and any resulting damage or loss Certai...

Страница 16: ...ipment In the interest of clarity some components may be shown disassembled or may not be shown at all It is not always necessary to disassem ble the component to perform the activity in question Plea...

Страница 17: ...15...

Страница 18: ...4 VIEW OF VEHICLE 16 4 1 View of vehicle front left side example 601816 11...

Страница 19: ...p 23 2 Clutch lever p 23 3 Handrails p 38 4 Filler cap 5 Fork compression adjustment 6 Engine number p 21 7 Shift lever p 39 8 Side stand p 40 9 Seat release p 37 9 Compression damping of the shock ab...

Страница 20: ...4 VIEW OF VEHICLE 18 4 2 View of vehicle rear right side example 601817 11...

Страница 21: ...teering lock p 27 3 Function buttons p 28 3 Indicator lamps p 29 4 Emergency OFF switch p 26 4 Electric starter button p 26 5 Throttle grip p 24 6 Fork rebound adjustment 7 Shock absorber rebound adju...

Страница 22: ...5 SERIAL NUMBERS 20 5 1 Chassis number 601858 10 The chassis number 1 is stamped on the steering head on the right 5 2 Type label B01289 10 The type label 1 is located on the right side of the frame...

Страница 23: ...key number 1 can be found on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place 5 4 Engine number 601860 10 The engine number 1 is stamped on the l...

Страница 24: ...S 22 5 5 Fork part number 601861 10 The fork part number 1 is stamped on the inner side of the fork stub 5 6 Shock absorber part number 601862 10 The shock absorber part number 1 is on the left of the...

Страница 25: ...lever 1 is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 6 2 Hand brake lever 601864 10 The hand break lever 1 is fitted on the right side of the han...

Страница 26: ...ttle grip 1 is fitted on the right side of the handlebar 6 4 Horn button 601865 12 The horn button 1 is fitted on the left side of the handlebar Possible states Horn button in neutral position Horn bu...

Страница 27: ...tched on 6 6 Turn signal switch 601865 11 The turn signal switch 1 is fitted on the left side of the handlebar Possible states Turn signal off Turn signal light left on Turn signal switch pressed to t...

Страница 28: ...ted a running engine stops and the engine cannot be started Emergency OFF switch on This position is necessary for operation as the ignition circuit is closed 6 8 Electric starter button 601866 11 The...

Страница 29: ...y can be removed Ignition ON In this position the ignition circuit is closed and the engine can be started Steering locked In this position the ignition circuit is interrupted and the steering locked...

Страница 30: ...eled ODO trip master 1 TRIP 1 and trip mas ter 2 TRIP 2 Press the SET button 2 to reset the trip master 1 function TRIP 1 and trip master 2 func tion TRIP 2 to 0 0 Button 3 has no function 6 10 3 Tach...

Страница 31: ...h beam indicator lamp lights up blue The high beam is switched on The temperature warning lamp lights up red The coolant temperature has reached a critical value The low fuel warning lamp lights up ye...

Страница 32: ...t up for a second as a function test 400881 01 LEnGth Following the display function test the LEnGth wheel circumference is shown for one sec ond Info 1870 mm corresponds to the circumference of the 1...

Страница 33: ...s shown in kilometers per hour km h or in miles per hour mph 6 10 7 Setting kilometers or miles Info If you change the unit the value ODO is retained and converted accordingly Making the setting accor...

Страница 34: ...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 10 8 Time 400838 11 The time is shown in area 1 of the display Info After reco...

Страница 35: ...and the SET button pressed simultaneously The time is set 6 10 10 ODO display 400839 01 In the ODO display mode the total distance traveled is shown in kilometers or miles Info This value is retained...

Страница 36: ...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 37: ...lamp lights up in parallel to the TRIP F display 6 10 14 Coolant temperature indicator 700124 01 The temperature display consists of 12 bars The more bars that light up the hotter the coolant When the...

Страница 38: ...ing Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc...

Страница 39: ...6 12 Closing filler cap 601868 01 Put the filler cap back on and turn the ignition key 90 clockwise Remove the ignition key and fold down the cover 6 13 Seat release 601869 10 The seat can be released...

Страница 40: ...have a passenger the passenger can hold on the handrails during the journey 6 15 Passenger footrests 601871 01 The passenger footrests can be folded up and down Possible states Passenger footrests fo...

Страница 41: ...6 16 Shift lever 601872 10 The shift lever 1 is mounted on the left side of the engine 601872 11 The gear positions can be seen in the photograph The neutral or idle position is between the first and...

Страница 42: ...hicle 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 tio...

Страница 43: ...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 44: ...service record at vehicle handover Before your first trip read the entire operating instructions carefully Get to know the controls Adjust the basic position of clutch lever p 84 Adjust the basic posi...

Страница 45: ...helmet baggage Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and or tank rucksack Mount and secure suitcase and tank rucksack according to the man...

Страница 46: ...ble handling characteristics due to slipped baggage Check the way your baggage is fixed regularly Warning Danger of burns A hot exhaust system can burn baggage Fasten your baggage in such a way that i...

Страница 47: ...d level p 92 Check the front brake linings p 89 Check the rear brake linings p 94 Check the brake system function Check the coolant level p 128 Check the chain for dirt p 76 Check the chain tension p...

Страница 48: ...safety equipment may be damaged Never operate the vehicle with a discharged battery or without a battery Note Engine failure High engine speeds in cold engines have a negative effect on the service li...

Страница 49: ...n a gear is engaged If the side stand is folded out and you shift into gear and release the clutch lever the engine stops Take the weight off the side stand and swing it back up with your foot as far...

Страница 50: ...rning the minimum age of passengers in your country Warning Danger of accidents Danger of accidents caused by dangerous driving Comply with traffic regulations and ride defensively and foresightedly t...

Страница 51: ...le as usual before preparing for use 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...

Страница 52: ...erably lower Accelerate only up 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...

Страница 53: ...em by riding and braking gently Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake Check the brake system and do not continue riding Your aut...

Страница 54: ...engine As a result you will have to apply the brakes far less frequently and the brake system will not overheat 8 6 Stopping parking Warning Risk of misappropriation Usage by unauthorized persons Nev...

Страница 55: ...s switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock power continues to flow to most power consumers and the battery will discharge You should therefo...

Страница 56: ...le Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel imme...

Страница 57: ...refuel with clean fuel that meets the specified standards Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the grou...

Страница 58: ...button 2 for two seconds The fuel level warning lamp 1 switches off TRIP F is set to 0 0 and the display returns to the previous display mode Info If you do not press the SET button 2 the reset takes...

Страница 59: ...and leakage Check the rear brake fluid level p 92 Check the free travel of the foot brake lever p 90 Check that the shock absorber and fork are leak tight If necessary and depending on use service th...

Страница 60: ...ed without sharp bends and set correctly Change the air filter Clean the air filter box x Check the fuel pressure x Check the CO adjustment with the KTM diagnostics tool x Check rectify the fluid leve...

Страница 61: ...9 SERVICE SCHEDULE 59 K10N Once after 1 000 km 621 4 mi K100A Every 10 000 km 6 214 mi or annually or after every sporting use K200A Every 20 000 km 12 428 mi or every 2 years...

Страница 62: ...he basis of your own personal suspension setting Do not change the settings at random or by more than 40 since otherwise the riding characteristics could deteriorate particularly at high speeds 10 2 A...

Страница 63: ...kwise to reduce damping 10 3 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork rebound behavior 601877 10 Turn adjusting screws 1 clockwise all the way I...

Страница 64: ...on the landing after a jump the rear wheel suspension compresses more quickly The low speed setting for example has an effect when riding over long ground swells the rear wheel suspension compresses m...

Страница 65: ...he shock absorber type Guideline Compression damping low speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full load capacity 15 clicks Info Turn clockwise to increase damping turn counterclo...

Страница 66: ...he shock absorber type Guideline Compression damping high speed Comfort 2 turns Standard 1 5 turns Sport 1 turn Full payload 1 turn Info Turn clockwise to increase damping turn counterclockwise to red...

Страница 67: ...s Info Turn clockwise to increase damping turn counterclockwise to reduce damping 10 8 Handlebar position 601874 10 In the upper triple clamp there are 2 drill holes separated by a distance of A Hole...

Страница 68: ...ve the two screws 2 Take off the handlebar holder Move the handlebar holder to the desired position Mount and tighten the two screws 2 Guideline Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 2...

Страница 69: ...e vehicle on a firm and even surface S00053 10 Stand the motorcycle upright on a level surface Raise the motorcycle in the area of the footrest bracket Secure the motorcycle against falling over 11 2...

Страница 70: ...with the rear wheel stand Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 601893 01 Insert the adapter into the rear wheel stan...

Страница 71: ...firm and even surface 601873 11 Secure the motorcycle against falling over Remove the rear wheel stand and lean the vehicle on the side stand 11 5 Raising the motorcycle with the front wheel stand No...

Страница 72: ...ays raise the rear of the motorcycle first Raise the front of the motorcycle 11 6 Taking the motorcycle off of the front wheel stand Note Danger of damage The parked vehicle may roll away or fall over...

Страница 73: ...tand p 67 Remove the fork protector p 72 L00350 10 Main work Push dust boots 1 on both fork legs downward Info The dust boots remove dust and coarse dirt particles from the inside fork tubes Over time...

Страница 74: ...back into their normal position Remove excess oil Finishing work Install the fork protector p 73 Remove the motorcycle from the lift stand p 67 11 9 Removing the fork protector S00054 12 Remove screw...

Страница 75: ...chassis M6 10 Nm 7 4 lbf ft Position the brake line and cable harness Put the clamp on mount and tighten screws 2 Position the fork protection on the right fork leg Mount and tighten the screws Guide...

Страница 76: ...me time push it forward Push locking pin 3 into lock housing 4 and push the back of the seat down until the locking pin locks in place with an audible click Finally check that the seat is correctly mo...

Страница 77: ...engine and result in increased wear Remove air filter 3 11 14 Installing the air filter x 601881 10 Main work Clean the air filter box Mount air filter 1 Info The air filter must lie flush against the...

Страница 78: ...Mount and tighten screws 3 Guideline Screw air filter box top M6 2 Nm 1 5 lbf ft Finishing work Mount the seat p 74 11 15 Checking the chain for dirt 400678 01 Check the chain for heavy soiling If th...

Страница 79: ...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 80: ...other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check the chain tension and correct if necessary 100249 10 Lean...

Страница 81: ...t rear sprocket bearings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On...

Страница 82: ...sition relative to the reference marks C The rear wheel is then correctly aligned Info The upper chain section must be taut Chain wear is not always even Repeat this measurement at different chain pos...

Страница 83: ...section of the chain with the specified weight A Guideline Weight of chain wear measurement 15 kg 33 lb Measure distance B of 18 chain links in the lower chain section Info Chain wear is not always ev...

Страница 84: ...r edge of the chain pins is in line with or below the chain sliding guard Replace the chain sliding guard x Check that the chain sliding guard is firmly seated If the chain sliding guard is loose Tigh...

Страница 85: ...nge the chain sliding piece x Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1...

Страница 86: ...of the rear wheel stand p 69 11 20 Adjusting basic position of clutch lever Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar Turn the adjusti...

Страница 87: ...hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc Do not use brake fluid Move the clutch fluid reservoir mounted on the handlebar to a horizontal position 100...

Страница 88: ...g 12 2 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc s Change the worn brake disc s without delay Your authorized KTM workshop will be glad to...

Страница 89: ...ark this indicates a leakage in 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 acciden...

Страница 90: ...th 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 a...

Страница 91: ...screws Info Clean up overflowed or spilt brake fluid immediately with water 12 5 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings C...

Страница 92: ...rake 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 601896 10 Move the foot brake...

Страница 93: ...01897 10 Loosen fitting 3 on foot brake cylinder 4 To adjust the basic position of the foot brake lever individually loosen nut 1 and turn screw 2 accordingly Info The range of adjustment is limited T...

Страница 94: ...Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help 601898 10 Stand the vehicle upright Check the brake fluid level...

Страница 95: ...fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil g...

Страница 96: ...2 10 Checking the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad...

Страница 97: ...ngs for minimum thickness A Minimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings x Check the brake linings for damage and cracking If there is...

Страница 98: ...r carefully back from the brake disc and hang it to one side Info Do not pull the handbrake lever when the brake caliper is removed 601902 10 Loosen screws 3 and 4 Unscrew screw 3 about 6 turns and pr...

Страница 99: ...brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary S00083 10 Main work Check the wheel bearing for damage and wear If the wheel bearing is...

Страница 100: ...ion the brake caliper and check that the brake linings are seated correctly Position spacers 3 Mount screws 4 but do not tighten Operate the hand brake lever repeatedly until the brake linings are in...

Страница 101: ...Screw fork stub M8 15 Nm 11 1 lbf ft Finishing work Take the motorcycle off of the rear wheel stand p 69 13 3 Removing rear wheel x Preparatory work Raise the motorcycle with the rear wheel stand p 6...

Страница 102: ...Info Do not operate the foot brake when the rear wheel is removed 13 4 Installing the rear wheel x Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always...

Страница 103: ...x Remove the bushing 1 Clean and grease the roll surfaces of the bushing and the shaft seal ring 2 Long life grease p 179 Clean and grease the thread of the wheel spindle and nut 3 Long life grease p...

Страница 104: ...4 in the same position Tighten nut 3 Guideline Nut rear wheel spindle M25x1 5 90 Nm 66 4 lbf ft Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and...

Страница 105: ...l rubber dampers in the rear hub 601905 10 Lay the rear wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub To check play A hold the rear wheel tight and...

Страница 106: ...ncontrollable handling characteristic due to non approved and or non recommended tires wheels Only tires wheels approved by KTM and with the corresponding speed index should be used Warning Danger of...

Страница 107: ...08 in If the tread depth is less than the minimum permissible depth Change the tires Check the age of the tires Info The tire s date of manufacture is usually part of the tire markings and is indi cat...

Страница 108: ...f inertia of these wheels are smaller than in conventional spoke wheels with a tube This results in better handling and riding comfort The rigid rim design results in a spoke wheel that is almost enti...

Страница 109: ...t meet specifications Correct tire pressure Mount the protection cap 13 9 Checking the spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension Ensure that the spoke...

Страница 110: ...cy of the tone is a function of the spoke length and spoke diameter If you hear different tone frequencies from individual spokes of the same length and thickness this is an indication of different sp...

Страница 111: ...t least 15 minutes and contact a physician Preparatory work Switch off all power consumers and switch off the engine Remove the seat p 73 601907 10 Main work Disconnect the negative minus cable of the...

Страница 112: ...Info The battery terminals must be at the rear Attach the positive cable and mount positive terminal cover 1 Position retaining bracket 2 Mount and tighten screws 3 Guideline Remaining screws chassis...

Страница 113: ...amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Warning Environmental hazard The battery contains elements that are harmful to the e...

Страница 114: ...are exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted from starting the vehicle repeatedly the battery must be charged immediately If...

Страница 115: ...rnator With this device you cannot overcharge the battery Info Never remove lid 1 Charge the battery with a maximum of 10 of the capacity specified on the bat tery housing 2 Switch off and disconnect...

Страница 116: ...Use only fuses with the prescribed amperage Never by pass or repair fuses Info The main fuse protects all power consumers in the vehicle It is in the housing of the starter relay next to the battery P...

Страница 117: ...ter relay Check the functioning of the electrical equipment Mount the protection covers Finishing work Mount the seat p 74 Set the clock p 32 14 5 Changing fuses of individual power consumers Info The...

Страница 118: ...ontrol unit Fuse 4 10 A fuel pump Fuse 5 10 A radiator fan Fuse 6 10 A horn brake light turn signal Fuse 7 15 A high beam low beam parking light tail light license plate lamp Fuse 8 10 A for supplemen...

Страница 119: ...es Replace with a spare fuse of the right rating Fuse 75011088010 p 166 Fuse 75011088015 p 166 Tip Put a new spare fuse in the fuse box for future use if needed Check the function of power consumers C...

Страница 120: ...09 10 Main work Cover the fender with a cloth to protect it from damage Remove screws 1 on both sides Tip the headlight mask forward 601910 10 Disconnect the connectors of turn signals 2 and headlight...

Страница 121: ...t mask with the headlight 601910 11 Main work Connect the connectors of headlight 1 and turn signal lights 2 Check lighting function 601911 10 Remove the cloth from the fender and position the headlig...

Страница 122: ...screws 7 Guideline Screw headlight mask M5 5 Nm 3 7 lbf ft Finishing work Check the headlight setting p 124 14 8 Changing the headlight bulb Note Damage to reflector Reduced brightness Grease on the l...

Страница 123: ...ke off protection cap 2 of the headlight bulb 600611 10 Detach spring bar 3 Remove headlight bulb 4 Insert a new headlight bulb into the headlight housing Headlight H4 socket P43t p 166 Fix the headli...

Страница 124: ...ease on the lamp will evaporate due to the heat and be deposited on the reflector Clean the lamp and keep it free of grease before mounting Preparatory work Switch off all power consumers and switch o...

Страница 125: ...1x9 5d p 167 Insert the bulb socket in the reflector Insert the protection cap Finishing work Install the headlight mask with the headlight p 119 Check the headlight setting p 124 14 10 Changing the...

Страница 126: ...ckwise until it stops Turn signal RY10W socket BAU15s p 167 Position the turn signal glass Insert the screw and turn it counterclockwise first until it engages in the thread Tighten the screw slightly...

Страница 127: ...specifications Adjust the headlight range p 125 14 12 Adjusting the headlight range Preparatory work Check the headlight setting p 124 C00193 10 Main work Turn adjusting screw 1 to adjust the headlig...

Страница 128: ...ture without causing any malfunctions 125 C 257 F 400407 10 Cooling takes place by means of the air stream and a radiator fan 4 which is controlled by a thermoswitch The lower the speed the less the c...

Страница 129: ...of the reach of children Condition Engine is cold C00188 11 Stand the motorcycle on its side stand on a horizontal surface Remove the cap of compensating tank 1 Check antifreeze of coolant 25 45 C 13...

Страница 130: ...specifications Correct the coolant level and find out the cause of the loss Alternative 1 Coolant p 174 Alternative 2 Coolant mixed ready to use p 174 Mount the radiator cap 15 3 Checking the coolant...

Страница 131: ...dren Condition Engine is cold C00188 11 Stand the motorcycle on its side stand on a horizontal surface Check the coolant level in the compensating tank 1 The coolant level must be within the range sho...

Страница 132: ...oning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin a...

Страница 133: ...sh affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolant out of the reach of ch...

Страница 134: ...running the engine always make sure there is sufficient 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...

Страница 135: ...poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engi...

Страница 136: ...e throttle cable by turning the adjusting screw 2 Guideline Throttle cable play 3 5 mm 0 12 0 2 in Tighten counter nut 1 16 3 Adjusting the engine characteristic Preparatory work Switch off the igniti...

Страница 137: ...extremely direct responsiveness Set the Map Select switch to Standard Set the adjusting wheel to position 3 4 5 6 7 8 or 9 Standard homologated performance with balanced responsiveness Set the Map Se...

Страница 138: ...ine distance A 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 specifications Adjust the...

Страница 139: ...lever 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 140: ...ng temperature Preparatory work Stand the motorcycle upright on a horizontal surface C00182 10 Main work Check the engine oil level Info After switching off the engine wait one minute before checking...

Страница 141: ...aining the engine oil x Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and safety gloves In case of burns rinse imme...

Страница 142: ...n the oil drain plug with a magnet Mount the oil drain plug with the magnet and seal ring and tighten it Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft 17 4 Removing the oil filter x W...

Страница 143: ...lace a suitable container under the engine 100202 10 Main work Remove screws 1 Remove the oil filter cover 2 with the O ring Pull oil filter 3 out of the oil filter housing Circlip pliers reverse 5101...

Страница 144: ...and safety gloves In case of burns rinse immediately with lukewarm water Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc...

Страница 145: ...Thoroughly clean the parts and sealing area 100207 10 Position oil screen 2 with the O rings Mount and tighten screw plug 1 with the O ring Guideline Plug oil screen M20x1 5 15 Nm 11 1 lbf ft 100208 1...

Страница 146: ...rew oil filter cover M5 6 Nm 4 4 lbf ft 17 7 Filling up with engine oil x Info Too little engine oil or poor quality engine oil results in premature wear to the engine C00179 10 Main work Remove fille...

Страница 147: ...hat it is oil tight Finishing work Check the engine oil level p 138 17 8 Adding engine oil Info Too little engine oil or poor quality engine oil results in premature wear to the engine C00179 10 Main...

Страница 148: ...sult 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 an enclosed space without an effective exhaust extra...

Страница 149: ...rs 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 direct...

Страница 150: ...o evaporate Push back the protection covers of the handlebar controls to allow any water that has penetrated to evaporate After the motorcycle has cooled off lubricate all moving parts and bearings Cl...

Страница 151: ...e p 147 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 the parts are cool...

Страница 152: ...Before storing the motorcycle check all parts for function and wear If service repairs or replacements are necessary you should do this during the storage period less workshop overload In this way you...

Страница 153: ...torcycle with the rear wheel stand p 68 Raise the motorcycle with the front wheel stand p 69 Cover the motorcycle with a tarp or cover that is permeable to air Info Do not use non porous materials sin...

Страница 154: ...the motorcycle off of the front wheel stand p 70 Take the motorcycle off of the rear wheel stand p 69 Recharge the battery x p 111 Install the battery x p 110 Set the clock p 32 Refuel p 54 Perform ch...

Страница 155: ...eutral Engine turns but does not start Operating error Carry out the start procedure p 46 Fuse 4 blown Change the fuses of individual power consumers p 115 Coupling of fuel hose connection not connect...

Страница 156: ...e KTM diag nostics tool x Engine dies during the journey Lack of fuel Refuel p 54 Fuse 1 2 or 4 blown Change the fuses of individual power consumers p 115 High oil consumption Engine vent hose bent Ro...

Страница 157: ...ernator Check the charging voltage x Check the quiescent current x Combination instrument shows nothing in the display Fuse 1 blown Change the fuses of individual power consumers p 115 Set the clock p...

Страница 158: ...y 9x Error level condition Manifold absolute pressure sensor cylinder 1 input signal too low Manifold absolute pressure sensor cylinder 1 input signal too high Blink code FI of warning lamp MIL 12 FI...

Страница 159: ...evel condition Rollover sensor input signal too low Rollover sensor input signal too high Blink code FI of warning lamp MIL 17 FI warning lamp MIL flashes 1x long 7x short Error level condition Lambda...

Страница 160: ...flashes 4x long 1x short Error level condition Fuel pump controller short circuit to ground or open circuit Fuel pump controller input signal too high Blink code FI of warning lamp MIL 45 FI warning l...

Страница 161: ...level condition Motor drive circuit fault Blink code FI of warning lamp MIL 90 FI warning lamp MIL flashes 9x long Error level condition Throttle position circuit fault Blink code FI of warning lamp M...

Страница 162: ...Valve diameter exhaust 34 mm 1 34 in Valve play cold 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 Pis...

Страница 163: ...starter automatic decompressor 22 2 engine tightening torques Screw membrane fixation M3 2 Nm 1 5 lbf ft Loctite 243 Hose clip intake flange M4 2 5 Nm 1 84 lbf ft Oil nozzle for conrod bearing lubrica...

Страница 164: ...w cylinder head M6 10 Nm 7 4 lbf ft Loctite 243 Screw engine case M6 10 Nm 7 4 lbf ft Screw ignition pulse generator M6 10 Nm 7 4 lbf ft Loctite 243 Screw locking lever M6 10 Nm 7 4 lbf ft Loctite 243...

Страница 165: ...hain shaft Step 1 15 Nm 11 1 lbf ft Step 2 30 Nm 22 1 lbf ft Step 3 45 Nm 33 2 lbf ft Step 4 60 Nm 44 3 lbf ft Lubricated with engine oil Oil line for oil pressure sensor M10x1 10 Nm 7 4 lbf ft Oil pr...

Страница 166: ...Nut inner clutch hub M20x1 5 100 Nm 73 8 lbf ft Loctite 243 Nut primary gear M20LHx1 5 90 Nm 66 4 lbf ft Loctite 243 Plug oil screen M20x1 5 15 Nm 11 1 lbf ft Plug timing chain tensioner M20x1 5 25 Nm...

Страница 167: ...Side Down 4860 ROMA Shock absorber WP Suspension 4618 with Pro Lever deflector Suspension travel Front 250 mm 9 84 in Rear 250 mm 9 84 in Brake system Front Disc brake with radially screwed four pisto...

Страница 168: ...aded 925 mm 36 42 in Ground clearance unloaded 270 mm 10 63 in Weight without fuel approx 142 kg 313 lb Maximum permissible front axle load 150 kg 331 lb Maximum permissible rear axle load 200 kg 441...

Страница 169: ...W 22 6 Tires Front tires Rear tires 120 70 R 17 M C 58H TL Continental Conti Attack SM 160 60 R 17 M C 69H TL Continental Conti Attack SM Additional information is available in the Service section und...

Страница 170: ...ber length 100 20 mm 3 94 0 79 in Fork length 900 mm 35 43 in Fork oil per fork leg 644 ml 21 77 fl oz Fork oil SAE 4 48601166S1 p 176 22 8 shock absorber Shock absorber part number 15 18 7L 12 Shock...

Страница 171: ...10 bar 145 psi Static sag 20 25 mm 0 79 0 98 in Riding sag 70 80 mm 2 76 3 15 in Fitted length 395 mm 15 55 in Shock absorber fluid Shock absorber oil SAE 2 5 50180342S1 p 176 22 9 chassis tightening...

Страница 172: ...Nm 2 2 lbf ft Screw electrical holder M5 3 Nm 2 2 lbf ft Screw exhaust heat shield M5 8 Nm 5 9 lbf ft Loctite 243 Screw fuel level sensor M5 3 Nm 2 2 lbf ft Screw fuel pump M5 4 Nm 3 lbf ft Screw fuel...

Страница 173: ...ctite 243 Screw seat lock M6 5 Nm 3 7 lbf ft Screw side cover M6 5 Nm 3 7 lbf ft Screw upper radiator bracket M6 10 Nm 7 4 lbf ft Screw voltage regulator M6 8 Nm 5 9 lbf ft Nut manifold on cylinder he...

Страница 174: ...8 4 lbf ft Screw rear footrest bracket M8x16 25 Nm 18 4 lbf ft Screw side stand bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw spring holder on side stand bracket M8 25 Nm 18 4 lbf ft Loctite 243 Scre...

Страница 175: ...18 4 lbf ft Copper paste Nut linkage lever on swingarm M14x1 5 100 Nm 73 8 lbf ft Nut linkage lever to rocker arm M14x1 5 100 Nm 73 8 lbf ft Screw bottom steering head M20x1 5 60 Nm 44 3 lbf ft Locti...

Страница 176: ...x 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 antifre...

Страница 177: ...sess the corresponding properties KTM recommends Motorex products Synthetic engine oil Supplier Motorex Cross Power 4T Engine oil SAE 10W 50 According to JASO T903 MA p 181 SAE p 181 SAE 10W 50 Guidel...

Страница 178: ...l that complies with the specified standard see specifications on the container and that possesses the corre sponding properties KTM recommends Motorex products Supplier Motorex Hydraulic Fluid 75 Sho...

Страница 179: ...aded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or...

Страница 180: ...lube for road use Guideline KTM recommends Motorex products Supplier Motorex Chainlube Road Cleaning and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Su...

Страница 181: ...grease Guideline KTM recommends Motorex products Supplier Motorex Bike Grease 2000 Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Paint cleaner and polish...

Страница 182: ...24 AUXILIARY SUBSTANCES 180 Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Synthetic...

Страница 183: ...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 184: ...t brake checking 87 rear brake checking 92 Brake linings front brake checking 89 rear brake checking 94 Brakes 51 Braking 51 C Capacity coolant 164 engine oil 144 164 fuel 55 165 Chain checking 80 cle...

Страница 185: ...tomer service 14 E Electric starter button 26 Emergency OFF switch 26 Engine running in 42 Engine characteristic adjusting 134 Engine number 21 Engine oil adding 145 changing 139 draining 139 refillin...

Страница 186: ...19 removing 117 Headlight setting checking 124 Horn button 24 I Ignition lock 27 Intended use 8 K Key number 21 L Light switch 25 Loading the vehicle 43 M Main fuse changing 114 Motorcycle cleaning 14...

Страница 187: ...Rear wheel fitting 100 removing 99 Riding 47 starting off 47 S Safe operation 10 Seat mounting 74 removing 73 Seat release 37 Service 13 Service schedule 57 59 Shift lever 39 basic position adjusting...

Страница 188: ...k 167 shock absorber 168 tires 167 Throttle grip 24 Tire air pressure checking 106 Tire condition checking 104 Transport 53 Troubleshooting 153 155 Tubeless tire system 106 Turn signal switch 25 Type...

Страница 189: ...3211954en 3211954en 11 2012 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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