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MAINTENANCE WORK ON CHASSIS AND ENGINE

57

9.5

Fork/shock absorber

100242-01

The fork and the shock absorber offer many options of adapting the chassis to your riding
style and the payload.

Info

To help you adapt the vehicle, we have summarized our findings in Table



. You

can find the table on the underside of the seat.

These adjustments should be understood 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 could deteriorate, particularly
at high speeds.

9.6

Adjusting the compression damping of the fork

Info

The hydraulic compression damping determines the fork suspension behavior.

600490-10

–

Turn adjusting screws



clockwise until they stop.

Info

The adjusting screws are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.

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Содержание Chassis 690 SMC

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

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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