OWNER'S MANUAL 2008 690 ENDURO EU 690 ENDURO AUS/UK ART. NO.
DEAR KTM CUSTOMER 1 Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. DEAR KTM CUSTOMER We wish you great pleasure riding the vehicle! Enter the serial numbers of your vehicle below. Chassis number ( P. 16) Engine number ( P. 17) Key number ( Dealer's stamp P.
DEAR KTM CUSTOMER 2 © 2008 by KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.
CONTENTS CONTENTS MEANS OF REPRESENTATION ............................................... 7 IMPORTANT NOTES ............................................................... 8 VIEW OF VEHICLE................................................................ 12 View of vehicle, front left side............................................ 12 View of vehicle, rear right side ........................................... 14 LOCATION OF SERIAL NUMBERS ......................................... 16 Chassis number........
CONTENTS 4 Stopping, parking ............................................................. Refueling......................................................................... GREASING AND SERVICE TABLE .......................................... Important maintenance work to be carried out by an authorized KTM workshop. ................................................ Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)...................
CONTENTS 5 Removing the seat .......................................................... Mounting the seat .......................................................... Removing the battery ................................................. Installing the battery .................................................. Recharging the battery ............................................... Changing the main fuse .................................................. Changing fuses of individual power consumers ..........
CONTENTS STANDARDS...................................................................... 171 INDEX ...............................................................................
MEANS OF REPRESENTATION MEANS OF REPRESENTATION 1 Symbols used The symbols used are explained in the following. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). All work marked with this symbol requires specialist knowledge and technical understanding.
IMPORTANT NOTES IMPORTANT NOTES 2 Use definition KTM sport motorcycles are designed and constructed to meet the normal demands of regular road and light offroad operation (dirt roads), but not for use on race courses. Info The motorcycle is authorized for public road traffic in the homologous version only. Maintenance A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in the owner's manual are properly carried out.
IMPORTANT NOTES 9 Spare parts, accessories For your own safety, use only spare parts and accessories approved by KTM, and have these mounted only in an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss. The current KTM PowerParts for your vehicle can be found on the KTM website. International KTM Website: http://www.ktm.com Transport Note Danger of damage Danger of damage by the vehicle running away or falling over.
IMPORTANT NOTES 10 Notes/warning notes Pay attention to the specified notes and warnings. Info Various notes and warning labels are attached to the vehicle. Do not remove any notes or warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured. Grades of risks Danger Danger that leads immediately and certainly to severe and permanent injury or death. Warning Danger that will probably lead to severe and permanent injury or death.
IMPORTANT NOTES – The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.
VIEW OF VEHICLE 12 VIEW OF VEHICLE 3 View of vehicle, front left side 3.
VIEW OF VEHICLE 1 Hand brake lever 2 Clutch lever 3 Handrail 4 Filler cap 5 Seat 6 Front brake caliper 7 Shift lever 8 Engine number 9 Side stand 10 Footrest 11 Seat release strap 13
VIEW OF VEHICLE 14 View of vehicle, rear right side 3.
VIEW OF VEHICLE 1 Ignition/steering lock 2 Rear mirror 3 Light switch, flasher switch, horn 4 Combination instrument 5 Emergency OFF switch, electric starter button 6 Throttle grip 7 Chassis number 8 Rear brake caliper 9 Passenger footrest 10 Shock absorber rebound damping 11 Foot brake pedal 12 Engine oil level viewer 15
LOCATION OF SERIAL NUMBERS LOCATION OF SERIAL NUMBERS 4 Chassis number 4.1 The chassis number is stamped on the steering head on the right. 100217-10 Type label 4.2 Type label is located on the upper right frame tube below the seat.
LOCATION OF SERIAL NUMBERS 17 Key number 4.3 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. 100179-10 Engine number 4.4 The engine number is stamped on the left side of the engine under the engine sprocket.
LOCATION OF SERIAL NUMBERS Fork part number 4.5 The fork part number is stamped on the inner side of the fork stub. 100214-10 Shock absorber part number 4.6 Shock absorber part number can be viewed from the right side.
OPERATING ELEMENTS 19 OPERATING ELEMENTS 5 Clutch lever 5.1 The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 100219-10 Hand brake lever 5.2 The hand break lever is fitted on the right side of the handlebar. The hand brake lever operates the front brake.
OPERATING ELEMENTS 20 Light switch 5.3 The light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is turned downwards. In this position, the low beam and tail 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. 500020-01 Light switch 5.4 The light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is turned downwards.
OPERATING ELEMENTS 21 Headlight flasher switch 5.5 The headlight flasher switch is fitted on the left side of the handlebar. Possible states • Headlight flasher switch in neutral position • Headlight flasher switch pressed – In this position, the headlight flasher (high beam) is actuated. 500020-11 Flasher switch 5.6 The flasher switch is fitted on the left side of the handlebar. Possible states Flasher light off Flasher light, left, on – Flasher switch pressed to the right.
OPERATING ELEMENTS 22 Flasher switch 5.7 The flasher switch is fitted on the left side of the handlebar. Possible states Flasher light off Flasher light, left, on – Flasher switch pressed to the right. The flasher switch returns automatically to the central position after use. Flasher light, right, on – Flasher switch pressed to the right. The flasher switch returns automatically to the central position after use. To switch off the flasher light, press the flasher switch towards the switch case.
OPERATING ELEMENTS 23 Horn 5.9 The horn button is fitted on the left side of the handlebar. Possible states • Horn button • Horn button in neutral position pressed – The horn is operated in this position. 100224-10 Emergency OFF switch 5.10 The emergency OFF switch is fitted on the left side of the handlebar. Possible states Emergency OFF switch off – In this position, the ignition circuit is interrupted, a running engine stops, and the engine cannot be started.
OPERATING ELEMENTS 24 Electric starter button 5.11 The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button • Electric starter button in basic position pressed – In this position, the electric starter is actuated. 100226-10 Ignition/steering lock 5.12 The ignition/steering lock is located in front of the seat.
OPERATING ELEMENTS 25 Combination instrument 5.13 The combination instrument is attached in fromt of the handlebar. The combination instrument is divided into 4 function areas. Function buttons Tachometer Indicator lights Display 700116-01 Combination instrument - function buttons 5.14 Press the MODE button to change the display mode. Possible display modes are total distance covered (ODO), tripmaster 1 (TRIP 1) and tripmaster 2 (TRIP 2).
OPERATING ELEMENTS 26 Combination instrument - tachometer 5.15 The tachometer displays the engine speed in revolutions per minute. The red marking shows the excess engine speed range. 100118-10 Combination instrument - control lamps 5.16 The indicator lamps provide additional information on the operating state of the motorcycle. Possible states Flashing indicator flashes green in flash rhythm – Flasher light is switched on. Idling speed indicator lamp lights up green – Transmission is in neutral.
OPERATING ELEMENTS 27 Battery warning lamp lights up – Voltage in electrical system too low. Combination instrument - Display 5.17 When you switch on the ignition, all display segments light up for a second as a function test. 700118-01 LEnGTth Following the display function test, the wheel circumference LEnGth is shown for one second. Info 2205 mm equals the circumference of the 21" front wheel with a series production tire. 400404-01 The display then changes to the last selected mode.
OPERATING ELEMENTS 28 Combination instrument - speed display 5.18 The speed is displayed in kilometers per hour km/h or miles per hour Mph. 700114-01 Setting kilometers or miles 5.19 Info If you change the unit, the ODO value is retained and converted accordingly. Making the setting according to the country. Condition The motorcycle is standing.
OPERATING ELEMENTS 29 – Switch on the ignition by turning the ignition key in the position – Press the MODE button several times until the ODO display mode is active. – Keep the MODE button pressed until the display mode changes from Km/h to Mph or from Mph to Km/h. . Specification Activation duration of MODE button 10 s 700120-01 Combination instrument - time 5.20 The time is shown in area of the display.
OPERATING ELEMENTS 30 – Switch on the ignition by turning the ignition key in the position – Press the MODE button several times until the ODO display mode is active. – Keep the MODE button and the SET button pressed simultaneously. . The time begins to flash. 700115-10 – Press the MODE button to adjust the hour. – Press the SET button to adjust the minute. – Keep the MODE button and the SET button pressed simultaneously. The time is set. Combination instrument - ODO display 5.
OPERATING ELEMENTS 31 – Switch on the ignition by turning the ignition key in the position – Press the MODE button several times until the TRIP 1 display mode is active. – Keep the SET button pressed. . The TRIP 1 display is at 0.0. 700121-01 Combination instrument - setting/resetting TRIP 2 display 5.24 Info The tripmaster TRIP 2 operates constantly and counts up to 999.9. You can use the tripmaster to measure trips or the distance between refuelling stops. After reaching 999.
OPERATING ELEMENTS 32 Combination instrument - TRIP F display 5.25 When the fuel level reaches the reserve mark, the display automatically changes to TRIP F and begins to count from 0.0, regardless of which display mode was previously active. Info Parallel to the TRIP F display, the fuel warning light begins to light up. 700123-01 Combination instrument - coolant temperature indicator 5.26 The temperature indicator in the display consists of 12 bars.
OPERATING ELEMENTS 33 Opening filler cap 5.27 – Lift the cover of the filler cap and insert the ignition key. – Turn the ignition key 90° counterclockwise and remove the filler cap. Info The filler cap has a tank air vent system. 100227-10 Closing filler cap 5.28 100228-01 – Put the filler cap back on and turn the ignition key 90° clockwise. – Remove the ignition key and fold down the cover.
OPERATING ELEMENTS 34 Handrails 5.29 The handrails are used for moving the motorcycle around. When you have a passenger, the passenger can hold on the handrails during the journey. 100229-10 Seat release 5.30 The seat can be released using strap .
OPERATING ELEMENTS 35 Passenger footrests 5.31 The passenger footrests 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. 100231-01 Shift lever 5.32 The shift lever is mounted on the left side of the engine.
OPERATING ELEMENTS 36 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 100212-10 Foot brake pedal 5.33 The footbrake pedal is located in front of the right footrest. The footbrake pedal operates the rear brake.
OPERATING ELEMENTS 37 Side stand 5.34 The side stand is coupled with the safety electric starter system - see the riding instructions. 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 – This position is mandatory for all journeys. The safety electric starter system is inactive.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 38 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 6 Advice on first use 6.1 Danger Danger of accidents Danger from inadequate traffic experience. – Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs. Warning Risk of injury Risk of injury by missing/inadequate protective clothing. – Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the motorcycle.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 39 Info When using your vehicle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover. – Before your first trip, read the entire operating instructions carefully. – Get to know the operating elements. – adjust the basic position of clutch lever.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 40 Running in the engine 6.2 – During the running-in phase, do not exceed the specified engine speed and engine performance. Specification Maximum engine speed – During the first: 1,000 km (621.4 mi) 6,000 rpm After the first: 1,000 km (621.4 mi) 7,800 rpm Avoid fully opening the throttle! Loading the vehicle 6.3 Warning Danger of accidents Unstable riding behavior. – Do not exceed the maximum permitted weight and axle loads.
GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 41 Warning Danger of accidents Poor visibility for other road users due to slipped baggage. – If the tail light is covered, you are less visible to following traffic, especially in the dark. Check the way your baggage is fixed regularly. Warning Danger of accidents Changed handling characteristics and longer stopping distance with excessive payload. – Adapt your speed according to your payload.
RIDING INSTRUCTIONS 42 RIDING INSTRUCTIONS 7 Checks before putting into operation 7.1 Info Make sure that the motorcycle is in a perfect technical condition before use. In the interests of riding safety, make a habit of making a general check before you ride. – Check the engine oil level. ( – Check the engine for loss of oil. – Check the fuel level. – Bleed fork legs. ( P. 133) P. 62) Specification all 1,000 km (621.4 mi) – Check the chain tension. ( – Clean the chain.
RIDING INSTRUCTIONS 43 Starting 7.2 Danger 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 engine in a closed space. Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety equipment may be damaged.
RIDING INSTRUCTIONS 44 – Turn the emergency OFF switch to the position – Switch on the ignition by turning the ignition key in the position . . After switching on the ignition, you can hear the fuel pump working for about 2 seconds. At the same time, the combination instrument runs a function test. – Shift gear to neutral. – Press the electric starter button The green idling speed indicator lamp N lights up. .
RIDING INSTRUCTIONS Starting up 7.3 – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully. Shifting, riding 7.4 Warning Danger of accidents An abrupt load alterations can cause the vehicle to get out of control. – Avoid abrupt load alterations and sudden braking actions, and adapt your speed to the road conditions. Warning Danger of accidents If you change down at high engine speed, the rear wheel can lock up.
RIDING INSTRUCTIONS 46 Warning Danger of accidents Reduced road grip with cold tires. – On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured. Warning Danger of accidents Reduced road grip with new tires. – New tires have a smooth roll surface and therefore cannot provide full road grip. The entire roll surface must be roughened in the first 200 kilometers (124.3 miles) by moderate driving at alternating angles.
RIDING INSTRUCTIONS 47 Note Engine failure Overheating of engine. – If the coolant temperature warning lamp lights up, stop and switch off the engine. Allow the engine to cool down and check the coolant level in the radiator, and top up if necessary. If you continue with the coolant temperature warning lamp alight, you may have engine failure. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.
RIDING INSTRUCTIONS 48 – For example, if the engine stalls at a junction, just pull the clutch and press the electric starter button. You do not need to shift into neutral. – Switch off the engine if you expect to be standing for a long time. – Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and the cooling system. – Ride with a lower engine speed instead of with a high engine speed and a slipping clutch.
RIDING INSTRUCTIONS 49 Warning Danger of accidents Brake system failure. – If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take your foot off the foot brake pedal if you do not want to brake. Warning Danger of accidents Longer stopping distance due to higher overall weight. – Take the longer stopping distance into account when carrying a passenger and baggage. Warning Danger of accidents Delayed brake action on salted roads.
RIDING INSTRUCTIONS 50 Warning Danger of burns Some vehicle components get very hot when the machine is driven. – Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these components to cool down before starting work on them. Note Danger of damage Danger of damage by the vehicle running away or falling over. – Always place the vehicle on a firm and even surface.
RIDING INSTRUCTIONS – Lock the steering by moving the handlebar to the left, pressing down the ignition key in the position and turning it to the position To make locking the steering easier, move the handlebar a little to the left and right. Remove the ignition key. 51 . Refueling 7.7 Danger Fire hazard Fuel can easily catch fire. – Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first.
RIDING INSTRUCTIONS 52 – switch off engine. – Open the filler cap. ( – Fill the fuel tank with fuel up to measurement . P. 33) Specification Measurement of Fuel tank content 400405-10 20 mm (0.79 in) 12 l (3.2 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( P. 168) – Close the filler cap. ( – Press the SET function button for 2 seconds. P. 33) The fuel level warning lamp switches off. TRIP F is set to 0 and appears in the previous display mode.
GREASING AND SERVICE TABLE 53 GREASING AND SERVICE TABLE 8 Important maintenance work to be carried out by an authorized KTM workshop. 8.1 Engine Change engine oil and oil filter, clean oil screens. Check and adjust valve clearance. x( P. 133) K10N K50A K100A J1A J2A • • • • • • x Check engine mounting screws for tightness. • • Replace spark plug. Fuel injection • • • • • Check engine bolts accessible from outside for tightness.
GREASING AND SERVICE TABLE Attachments Brakes 54 K10N K50A K100A J1A J2A Check the functioning of the electrical equipment. • • • • • Check screws and nuts for tightness. • • • • • Check the front brake linings. ( • • • • • • • • • • • • • • • • • • • • • • • • • Check the rear brake linings. ( Check the brake discs. ( P. 81) P. 89) P. 75) Check the front brake brake fluid level. ( Check the rear brake fluid level. ( Change brake fluid. P. 78) P.
GREASING AND SERVICE TABLE Wheels Check the chain wear. ( 55 P. 74) Check rear sprocket / engine sprocket for tightness. Check rear sprocket / engine sprocket for wear. ( Check the chain tension. ( Clean the chain. ( P. 73) P. 70) P. 69) Check wheel bearing for play. x Checking the rear hub rubber dampers. x( P. 97) K10N K50A K100A J1A J2A • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • J1A J2A K10N: after 1,000 km (621.
MAINTENANCE WORK ON CHASSIS AND ENGINE 56 MAINTENANCE WORK ON CHASSIS AND ENGINE 9 Jacking up the motorcycle 9.1 Note Danger of damage Danger of damage by the vehicle running away or falling over. – Always place the vehicle on a firm and even surface. – Jack up the motorcycle on the underride guard underneath the engine. The wheels must no longer touch the ground. – Secure the motorcycle against falling over. 100241-01 Removing the motorcycle from the work stand 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE 57 Fork/shock absorber 9.3 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. 100242-01 These adjustments should be understood as a guideline and should always be the basis of your own personal chassis adaptation.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 58 Turn back counterclockwise the number of clicks corresponding to the fork type. Specification Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping. – Mount protection covers . Adjusting rebound damping of fork 9.5 Info The hydraulic rebound damping determines the fork suspension behavior.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 59 Turn back counterclockwise the number of clicks corresponding to the fork type. Specification Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping. Compression damping of shock absorber 9.6 The shock absorber can regulate compression damping in low- and high-speed range separately (Dual Compression Control).
MAINTENANCE WORK ON CHASSIS AND ENGINE – 60 Turn the adjusting screw clockwise with a screwdriver until it stops. Info Do not loosen nut ! – Turn back counterclockwise the number of clicks corresponding to the shock absorber type. Specification Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.
MAINTENANCE WORK ON CHASSIS AND ENGINE 61 Info The high-speed setting can be seen during the fast compression of the shock absorber. – Turn the adjusting screw clockwise with an open-ended spanner until it stops. Info Do not loosen nut ! – Turn back counterclockwise the number of turns corresponding to the shock absorber type. Specification Compression damping, high-speed Comfort 2 turns Standard 1.
MAINTENANCE WORK ON CHASSIS AND ENGINE 62 Adjusting rebound damping of the shock absorber 9.9 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 maintenance on it yourself. – Turn the adjusting screw clockwise until it stops. – Turn back counterclockwise the number of clicks corresponding to the shock absorber type.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 63 Remove bleeder screws briefly. Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. Info Carry out this action on both fork legs. 100248-10 Cleaning dust boots of fork legs 9.11 – Jack up the motorcycle. ( – Loosen the fork protection. ( – Push dust boots of both fork legs downwards. P. 56) P. 64) Info The dust boots should remove dust and coarse dirt particles from the fork tubes.
MAINTENANCE WORK ON CHASSIS AND ENGINE 64 – Remove excess oil. – Position the fork protection. ( – Remove the motorcycle from the work stand. ( – Remove screws and take off clamp. – Remove screws on left fork leg. Push the fork protection downwards. – Remove the screws on the right fork leg. Push the fork protection downwards. – Position the fork protection on the left fork leg. Mount and tighten screws . P. 64) P. 56) Loosening the fork protection 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking play of steering head bearing 9.14 65 x Warning Danger of accidents Unsafe riding behavior due to incorrect steering head bearing play. – The steering head bearing play should be adjusted immediately in an authorized KTM workshop. Info If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time. – Jack up the motorcycle.
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting play of steering head bearing 9.15 66 x – Jack up the motorcycle. ( – Loosen screw . Remove screw . – Loosen and retighten screw . P. 56) Specification Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft) – Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. – Fully tighten screw . Specification Screw, top triple clamp 100297-10 – M8 17 Nm (12.5 lbf ft) Mount and tighten screw .
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the handlebar angle 9.16 67 x – Loosen screw . – Move the handlebar to the desired position and slightly tichten the screws. – Move the handlebar carefully in both directions as far as it will go. » If the handlebar instruments touch the fuel tank: – Correct the handlebar angle. Info The distance between the handlebar support and the handlebar clamp must be the same at the front and rear. 100279-10 – Fully tighten screw .
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting handlebar position 9.18 68 x – 1 0 2 0 Remove the four screws . Remove the handlebar clamp. Remove the handlebar and lay it to one side. Info Protect the motorcycle and its attachments from damage by covering them. Do not bend 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 .
MAINTENANCE WORK ON CHASSIS AND ENGINE Checking chain dirt 9.19 – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( P. 69) Cleaning the chain 9.20 Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking due to oil or grease on the brake discs.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 70 After drying, apply chain spray. Offroad chain spray ( P. 170) Checking the chain tension 9.21 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load.
MAINTENANCE WORK ON CHASSIS AND ENGINE 71 – Lean the motorcycle on the side stand. – Shift gear to neutral. – Push the chain upward at a distance from the chain sliding guard and determine the chain tension . Info The upper chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions. » Chain tension 5 mm (0.2 in) Distance to chain sliding guard 30 mm (1.
MAINTENANCE WORK ON CHASSIS AND ENGINE 72 – Lean the motorcycle on the side stand. – Shift gear to neutral. – Loosen nut . – Loosen nuts . – Adjust the chain tension by turning the adjusting screws left and right. Specification Chain tension 5 mm (0.2 in) Turn the adjusting screws left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks . The rear wheel is then correctly aligned.
MAINTENANCE WORK ON CHASSIS AND ENGINE 73 Checking rear sprocket / engine sprocket for wear 9.23 – Check rear sprocket / engine sprocket for wear. » If the rear 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 joint. Always have the chain replaced in an authorized KTM workshop, where the necessary chain rivet tool is available.
MAINTENANCE WORK ON CHASSIS AND ENGINE 74 Checking chain wear 9.24 – Shift into neutral, pull the lower chain section with the specified weight . Specification Weight of chain wear measurement – 15 kg (33 lb.) Measure the distance of 18 chain links in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions.
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting chain guide 9.25 75 x – Remove screws and . Take off the chain guide. Conditions Number of teeth: ≤ 44 teeth – Insert nut in hole . Position the chain guide. – Mount and tighten screws and . Specification Remaining screws, chassis M6 10 Nm (7.4 lbf ft) Conditions Number of teeth: ≥ 45 teeth – Insert nut in hole . Position the chain guide. – Mount and tighten screws and .
MAINTENANCE WORK ON CHASSIS AND ENGINE – 76 Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement . Info Wear reduces the thickness of the brake disc around the area used by the brake linings.. Wear limit of brake discs 400406-10 » front 4.5 mm (0.177 in) Rear 3.5 mm (0.138 in) If the brake disc thickness is less than the specified value: – Change the brake disc. Checking free play of hand brake lever 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 77 Push the hand brake to the handlebar and check free play . Free play of hand brake lever » ≥ 3 mm (≥ 0.12 in) If the free travel does not meet specifications: – Adjust the free travel of the handbrake lever. ( P. 77) 100251-10 Adjusting free travel of handbrake lever 9.28 – Adjust the free travel of the handbrake lever with the adjustment screw . Info Turn the adjustment screw clockwise to reduce free travel.
MAINTENANCE WORK ON CHASSIS AND ENGINE 78 Checking front brake fluid level 9.29 Warning Danger of accidents Brake system failure. – MINIf the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further. Warning Danger of accidents Reduced braking due to old brake fluid.
MAINTENANCE WORK ON CHASSIS AND ENGINE 79 Warning Skin irritations Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screws . – Remove cover with membrane . – Add brake fluid to level . 80 Specification Measurement of Brake fluid DOT 4 / DOT 5.1 ( 100254-10 5 mm (0.2 in) P. 166) – Check parts for damage and wear. Replace damaged or worn parts. – Position the cover with the membrane. Mount and tighten screws. Info Clean up overflowed or spilt brake fluid immediately with water. Brake linings 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE 81 Checking the front brake linings 9.32 Warning Danger of accidents Reduced braking due to worn brake linings. – Worn brake linings should be replaced immediately in an authorized KTM workshop. Note Danger of accidents Reduced braking due to damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are destroyed.
MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Skin irritations Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws . – Remove the cover with membrane . – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons. Ensure that brake fluid does not overflow from the brake fluid reservoir and suction it off if necessary. 83 Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.
MAINTENANCE WORK ON CHASSIS AND ENGINE 84 – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. – Insert the brake pads, insert the bolt and mount the split pin. – Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot. – Adjust the brake fluid level to level . 400418-10 100291-01 Specification Measurement of Brake fluid DOT 4 / DOT 5.1 ( – 5 mm (0.2 in) P.
MAINTENANCE WORK ON CHASSIS AND ENGINE 85 Checking free play of foot brake lever 9.34 Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can fail due to overheating. Adjust free travel on foot brake pedal according to specifications. – 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 .
MAINTENANCE WORK ON CHASSIS AND ENGINE 86 – Remove screw connection on foot brake cylinder . – To adjust the basic position of the foot brake pedal as needed, loosen nut and turn screw accordingly. Info The range of adjustment is limited. The screw must be screwed into the footrest bracket by at least four turns. – Position foot brake cylinder so that the foot brake pedal has the necessary free travel. Hold screws in place and tighten the nuts.
MAINTENANCE WORK ON CHASSIS AND ENGINE 87 Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. – Stand the vehicle upright. – Check the brake fluid level in the brake fluid reservoir. » If the fluid level reaches the MIN marking : – Top up the brake fluid of the rear brake. x( P. 87) 100258-10 Topping up brake fluid of rear brake 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according 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, batteries, etc. according to regulations. Info Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple.
MAINTENANCE WORK ON CHASSIS AND ENGINE 89 Checking the rear brake linings 9.38 Warning Danger of accidents Reduced braking due to worn brake linings. – Worn brake linings should be replaced immediately in an authorized KTM workshop. Note Danger of accidents Reduced braking due to damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are destroyed.
MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Skin irritations Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.
MAINTENANCE WORK ON CHASSIS AND ENGINE 91 – Stand the vehicle upright. – Remove screw cover with membrane . – Press the brake caliper by hand on to the brake disc in order to press back the brake piston. Ensure that brake fluid does not overflow from the brake fluid reservoir and suction it off if necessary. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Insert the brake pads, insert the bolt and mount the split pin. – Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot. – Adjust the brake fluid level to the MAX mark. Brake fluid DOT 4 / DOT 5.1 ( – P. 166) Refit screw with membrane. Info 100289-01 Removing front wheel 9.40 Clean up overflowed or spilt brake fluid immediately with water. x 100261-01 92 – Jack up the motorcycle.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screw . – Loosen screw . – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. 100262-10 Info Do not pull the hand brake lever when the front wheel is removed. Always lay the wheel down in such a way that the brake disc is not damaged. 100263-10 – 100264-10 Remove the spacing sleeves .
MAINTENANCE WORK ON CHASSIS AND ENGINE Fitting front wheel 9.41 94 x Warning Danger of accidents 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. – Check parts for damage and wear. Replace damaged or worn parts. – Clean and grease shaft seal rings and bearing surface of the spacing sleeves. Long-life grease ( P. 170) – Fit the spacing sleeves.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 95 Fully tighten screw . Specification Screw, fork stub Removing rear wheel 9.42 M8 15 Nm (11.1 lbf ft) x – Jack up the motorcycle. ( – Press the brake caliper by hand on to the brake disc in order to press back the brake piston. – Remove nut . Remove chain adjuster . – Holding the rear wheel, withdraw the wheel spindle . – Push the rear wheel forwards as far as possible and take the chain off the rear sprocket. P.
MAINTENANCE WORK ON CHASSIS AND ENGINE Fitting rear wheel 9.43 96 x Warning Danger of accidents 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 Danger of accidents No braking effect when operating the rear brake. – After installing the rear wheel, always operate the footbrake until the pressure point is reached. – Checking the rear hub rubber dampers.
MAINTENANCE WORK ON CHASSIS AND ENGINE 97 – Push the rear wheel forward as far as possible and place the chain on the rear sprocket. – Mount the wheel spindle, chain adjuster and nut. Specification In order for the rear wheel to be correctly aligned, the markings on the left and right chain adjusters must be in the same position relative to the reference marks . Info Fit the chain left and right adjusters in similar positions. 100270-10 – Tighten nut .
MAINTENANCE WORK ON CHASSIS AND ENGINE – 98 Check 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. 100271-10 – Lay the read wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub. – To check the play , hold the rear wheel tight and try to rotate the rear sprocket. Info Measure the play on the outside of the rear sprocket.
MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of crashing Impairment of riding behavior 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 over the vehicle. Warning Danger of accidents Uncontrollable handling behavior caused by non-approved tires/wheels. – Use only tires/wheels approved by KTM with the corresponding speed index.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 100 Check the depth of the tread. Info Note local national regulations concerning the minimum tread depth. Minimum tread depth » If the minimum tread depth is insufficient: – Change the tires. Checking tire air pressure 9.46 Info Low tire air pressure leads to abnormal wear and overheating of the tire. Correct tire air pressure ensures optimal riding comfort and maximum tire service life. – 100274-01 ≥ 2 mm (≥ 0.08 in) Remove dust cap.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 101 Check tire air pressure when tires are cold. Tire air pressure, offroad, single rider front 1.5 bar (22 psi) Rear 1.5 bar (22 psi) Tire air pressure, road, solo front 1.8 bar (26 psi) Rear 1.8 bar (26 psi) Tire air pressure with passenger / fully loaded » 2.0 bar (29 psi) Rear 2.2 bar (32 psi) If the tire pressure does not meet specifications: – – front Correct tire pressure. Mount dust cap. Checking spoke tension 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 102 To check spoke tension, tap each spoke with a screwdriver. Specification You should hear a high note. Spoke nipple, front wheel M5 4 Nm (3 lbf ft) Spoke nipple, rear wheel M5 4 Nm (3 lbf ft) Info If you hear different tone frequencies from different spokes, this is an indication of different spoke tensions. 100275-01 Removing the seat 9.48 100230-10 – Pull on strap and raise the rear of the seat at the same time.
MAINTENANCE WORK ON CHASSIS AND ENGINE 103 Mounting the seat 9.49 – Hook slot of the seat onto screw , press the rear downward and at the same time push it forward. – Push locking pin into lock housing 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 mounted. 100276-10 Removing the battery 9.50 x Warning Risk of injury Battery acid and battery gases cause serious cauterization.
MAINTENANCE WORK ON CHASSIS AND ENGINE 104 – Disconnect the negative (minus) cable of the battery. – Pull off connector in an upward direction. – Remove screws . – Pull retaining bracket of the battery forward and remove it. – Take off the positive terminal cover . – Disconnect the positive (plus) cable of the battery. – Press the wiring harness to one side and pull the battery out of the battery rack.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Recharging the battery 9.52 Set the clock. ( 105 P. 29) x Warning Risk of injury Battery acid and battery gases cause serious cauterization. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. – Keep the battery away from sparks or open fire. Charge only in well ventilated rooms. – In the event of skin contact, rinse with large amounts of water.
MAINTENANCE WORK ON CHASSIS AND ENGINE 106 Info Even if there is no load on the battery, it loses power every day. The charge state and the type of charge are very important for the service life of the battery. Fast recharging with a high charge current shortens the battery's service life. If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes. The battery capacity is then reduced.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 107 Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the battery, and to test the generator. With this device, you cannot overcharge the battery. Info Never remove the lid . Charge the battery according to the instructions on the battery casing. – After charging, switch off and disconnect the battery charger.
MAINTENANCE WORK ON CHASSIS AND ENGINE 108 Info The main fuse protects all power-consuming components of the vehicle. It is located in the housing of the electric starter relay next to the battery. – Switch off all power-consuming components and switch off the engine. – Remove the seat. ( – Remove protection covers . – Remove a defective main fuse with a needle nose plier. – Check parts for damage and wear. Replace damaged or worn parts. P.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Attach the protection covers. – Mount the seat. ( – Set the clock. ( P. 103) P. 29) Changing fuses of individual power consumers 9.54 Info The fuse box containing the fuses of individual power consumers is located under the seat. 600604-11 – Switch off all power-consuming components and switch off the engine. – Remove the seat. ( – Open the fuse box cover . P.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove defective fuse.
MAINTENANCE WORK ON CHASSIS AND ENGINE 111 Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses. – – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Use spare fuses with the correct rating only. Fuse (75011088010) ( P. 158) Fuse (75011088015) ( P. 158) Info If the new fuse burns out, contact an authorized KTM workshop. Tip Replace the spare fuse in the fuse box so that it will be available if needed.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Pull the Map‑Select switch and holder upward off of the retaining bracket. – Pull the Map‑Select switch out of the holder. – Turn the adjusting wheel until the desired digit is next to marking . 112 100237-10 Set the Map‑Select switch to Soft. – Set the adjusting wheel to position 1. Soft – reduced homologated peak performance for better driveability. Set the Map‑Select switch to Advanced. – Set the adjusting wheel to position 2.
MAINTENANCE WORK ON CHASSIS AND ENGINE Removing headlight mask with headlight 9.56 – Switch off all power-consuming components and switch off the engine. – Protect the fender against damage by covering it with a cloth. – Remove the screws on the left and right. – Tilt the headlight mask forward and lift it off. – Disconnect the connectors of flasher lights and headlight . – Place the headlight mask to one side.
MAINTENANCE WORK ON CHASSIS AND ENGINE 114 Refitting the headlight mask with the headlight 9.57 – Connect the connectors of headlight and flasher lights . – Check lighting function. – Remove the cloth from the fender, attach the headlight mask to points on the fender and swing it up to the steering head.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 115 Position brake-hose guide . Mount and tighten screws . Specification Remaining screws, chassis M6 10 Nm (7.4 lbf ft) 100296-10 Changing the headlight bulb 9.58 Note Damage to reflector Keep the glass of the bulb free of grease. – Clean the glass bulb with a clean cloth before mounting. Any grease on the glass will evaporate by the heat and be deposited on the reflector. 600610-10 – Remove the headlight mask with the headlight.
MAINTENANCE WORK ON CHASSIS AND ENGINE 116 – Detach spring bar . – Remove headlight bulb . – Insert a new headlight bulb into the headlight housing. Headlight (H4/P43t) ( P. 158) – Fit the headlight bulb in the headlight using the spring bar. – Replace the rubber cap. Attach the connector. – Refit the headlight mask with the headlight. ( P. 114) 600611-10 Changing the parking light bulb 9.59 Note Damage to reflector Keep the glass of the bulb free of grease.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Pull bulb socket out of the reflector. – Pull parking light bulb out of the bulb socket. – Check parts for damage and wear. Replace damaged or worn parts. – Insert a new parking light bulb into the bulb socket. Parking light (W2,1x9,5d) ( 600612-10 117 P. 158) – Insert the bulb socket into the reflector. – Insert the rubber cap. – Refit the headlight mask with the headlight. ( P. 114) Changing the flasher bulb 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 118 Press the new flasher bulb carefully into the holder and turn it clockwise as far as it will go. Flasher light (BA15s) ( P. 158) – Mount the orange cap. – Position the diffuser. – Insert the screw and turn it first counterclockwise until you feel it click into the thread. Tighten the screw. – Check the flasher function. – On a light-colored wall with a horizontal area in front of it, make a mark as high as the center of the low beam headlight.
MAINTENANCE WORK ON CHASSIS AND ENGINE 119 Adjusting the headlight range 9.62 – Check the headlamp setting. ( – Use a screwdriver (see illustration) to adjust the headlight range. P. 118) Specification The boundary between light and dark must be exactly on the lower mark for a motorcycle with a rider (mark is applied under: Checking headlight adjustment). Info Turn clockwise to increase the light range, turn counterclockwise to reduce the light range.
MAINTENANCE WORK ON CHASSIS AND ENGINE 120 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. – Remove air filter . – Check parts for damage and wear. Change damaged or worn parts. Change the air filter if it is dirty or wet. – Clean the air filter box. – Mount air filter . 100286-10 Installing the air filter 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 121 Mount and tighten screws . Specification Remaining screws, chassis – Mount the seat. ( M6 10 Nm (7.4 lbf ft) P. 103) 100285-11 Cooling system 9.65 The water pump in the engine forces the coolant to flow. The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap . Heat expansion causes excess coolant to flow into the compensating tank .
MAINTENANCE WORK ON CHASSIS AND ENGINE 122 The coolant is cooled by the air stream and a radiator fan , which is controlled by a thermoswitch. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect. 400407-10 Checking the antifreeze and coolant level 9.66 Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure.
MAINTENANCE WORK ON CHASSIS AND ENGINE 123 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… −45 °C (−13… −49 °F) » 100283-10 If the antifreeze of the cooling liquid does not meet specifications: – – Correct antifreeze of coolant. Check the coolant level in the compensating tank. The coolant level must be within the range shown in the figure.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Screw off the radiator cap . – Check antifreeze of coolant. 124 −25… −45 °C (−13… −49 °F) » If the antifreeze of the cooling liquid does not meet specifications: – – Correct antifreeze of coolant. Check the coolant level in the radiator. The radiator must be completely full. 100284-10 » If the level of the cooling liquid does not meet specifications: – Correct the coolant level and find out the cause of the loss. Alternative 1 Coolant ( P.
MAINTENANCE WORK ON CHASSIS AND ENGINE 125 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 and contact a doctor. Wash 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 coolants out of the reach of children. Condition Engine is cold.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 126 Screw off the radiator cap and check the coolant level in the radiator. The radiator must be completely full. » If the level of the cooling liquid does not meet specifications: – Correct the coolant level and find out the cause of the loss. Alternative 1 Coolant ( P. 166) Alternative 2 100284-10 Coolant (mixed ready to use) ( – Draining coolant 9.68 P. 166) Refit the radiator cap.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Stand the vehicle upright. – Place a suitable container under the engine. – Remove screw . Remove the radiator cap. – Completely drain the coolant. – Fit screw with a new seal and tighten it. 127 Specification Plug, drain hole of water pump 600616-10 Filling the cooling system 9.69 – Install the engine guard. ( M10x1 15 Nm (11.1 lbf ft) P. 132) x Warning Danger of poisoning Coolants are poisonous and a health hazard.
MAINTENANCE WORK ON CHASSIS AND ENGINE – 128 Refill the coolant. Alternative 1 Coolant ( P. 166) Alternative 2 Coolant (mixed ready to use) ( P. 166) – Fill the radiator completely with coolant. Mount radiator cap . – Remove the cap from compensating tank and add coolant to the level shown in the figure. – Mount the cap of the compensating tank. 600619-10 Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death.
MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting basic position of clutch lever 9.70 Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screws . – Remove the cover with membrane . – Check the fluid level. Fluid level under top level of container. » 4 mm (0.16 in) If the fluid level does not meet specifications: – Correct the fluid level of the hydraulic clutch. Hydraulic fluid (15) ( 100281-10 130 P. 167) – Check parts for damage and wear. Replace damaged or worn parts. – Position the cover with the membrane. Mount and tighten screws.
MAINTENANCE WORK ON CHASSIS AND ENGINE 131 Danger 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 engine in a closed space. Start the engine and let it run idle. Move the handlebar to and fro over the entire steering range. The idle speed must not change. » If the idle speed changes: – Adjusting play in gas Bowden cable 9.
MAINTENANCE WORK ON CHASSIS AND ENGINE 132 Removing the engine guard 9.74 – Stand the motorcycle on its side stand on a horizontal surface. – Remove screws on the left and right. – Pull the engine guard forward out of the holders and set it down. – Slide the engine guard into holders at the rear. – Position the engine guard. Mount and tighten screws. 100198-10 Installing the engine guard 9.75 Specification Remaining screws, chassis 100199-10 M6 10 Nm (7.
MAINTENANCE WORK ON CHASSIS AND ENGINE 133 Checking engine oil level 9.76 Info The engine oil level must be checked when the engine is at operating temperature. – Stand the motorcycle upright on a horizontal surface. Condition The engine is at operating temperature. – Check 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE Draining engine oil 9.78 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 under cold water immediately. Warning Environmental hazard Problem materials cause environmental damage. – Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
MAINTENANCE WORK ON CHASSIS AND ENGINE 135 – Thoroughly clean the oil drain plug with a magnet. – Check parts for damage and wear. Replace damaged or worn parts. – Refit the oil drain plug with the magnet and seal ring and tighten it. Specification Oil drain plug with magnet M12x1,5 20 Nm (14.8 lbf ft) 100201-01 Removing the oil filter 9.79 x Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. – Wear suitable protective clothing and gloves.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screws . Remove oil filter cover with O-ring. – Pull the oil filter insert out of the oil filter casing. Circlip pliers reverse (51012011000) 100202-10 – Remove screws . Remove oil filter cover with O-ring. – Pull the oil filter insert out of the oil filter casing. Circlip pliers reverse (51012011000) 100203-10 – Completely drain the engine oil. – Thoroughly clean parts and sealing area.
MAINTENANCE WORK ON CHASSIS AND ENGINE Mounting oil filter 9.80 137 x – Check parts for damage and wear. Replace damaged or worn parts. – Insert oil filter and . – Oil the O-rings of the oil filter cover. Refit the oil filter cover and . – Mount and tighten screws. Specification Screw, oil filter cover M5 6 Nm (4.4 lbf ft) 100204-10 Cleaning oil screens 9.81 x Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven.
MAINTENANCE WORK ON CHASSIS AND ENGINE 138 – Remove the plug with the oil screen and O-rings. – Remove the plug with the oil screen and O-rings. – Drain the remaining engine oil. – Thoroughly clean parts and sealing area. – Check parts for damage and wear. Replace damaged or worn parts. – Position oil screen with O-rings. – Refit plug with O-ring and tighten it. 100205-10 100206-10 Specification Plug, oil screen 100207-10 M20x1,5 15 Nm (11.
MAINTENANCE WORK ON CHASSIS AND ENGINE – Position oil screen with O-rings. – Refit plug with O-ring and tighten it. 139 Specification Plug, oil screen M20x1,5 15 Nm (11.1 lbf ft) 100208-10 Filling up with engine oil 9.82 x Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – Remove filler plug with O-ring from the clutch cover and add engine oil. Engine oil – 1.70 l (1.8 qt.) Engine oil (SAE 10W/60) ( P.
MAINTENANCE WORK ON CHASSIS AND ENGINE 140 Topping up engine oil 9.83 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – Remove filler plug with O-ring from the clutch cover and add engine oil. Engine oil (SAE 10W/60) ( – P. 167) Refit plug with O-ring and tighten it. Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death.
TROUBLESHOOTING 141 TROUBLESHOOTING 10 Faults Possible cause Action Engine does not turn when the electric starter button is pressed Operating error – Carry out the instructions for starting. ( P. 43) Battery discharged – Recharge the battery. – Check the cause of discharging. Fuse 1, 2, 3, or 4 blown – Change the fuses of individual power consumers. ( P. 109) Main fuse burned out – Change the main fuse.
TROUBLESHOOTING 142 Faults Possible cause Action Engine has too little power. Fuel filter very dirty – Have the fuel filter changed. Defect in fuel injection system – Read the error memory with the KTM diagnostics tool and correct the fault. Too little coolant in cooling system – Check the cooling system for leakage. – Check the coolant level. ( Radiator fins very dirty – Clean radiator fins. Foam formation in cooling system – Drain the coolant. – Fill the cooling system.
TROUBLESHOOTING 143 Faults Possible cause Action Headlight and parking light not functioning Fuse 7 blown – Change the fuses of individual power consumers. ( P. 109) Flasher light, brake light and horn not functioning Fuse 6 blown – Change the fuses of individual power consumers. ( P. 109) Time is not (correctly) displayed Fuse 2 blown – Change the fuses of individual power consumers. ( P. 109) – Set the clock.
FLASHING CODE 144 FLASHING CODE 11 Fault Description Possible cause Action 02 FI warning lamp (MIL) flashes briefly 2x Malfunction in ignition pulse generator circuit – Check the ignition pulse generator. 06 FI warning lamp (MIL) flashes briefly 6x Input signal from throttle valve sensor too low/high – Check the throttle valve sensor.
FLASHING CODE 145 Fault Description Possible cause Action 27 FI warning lamp (MIL) flashes 2x long, 7x short Malfunction in voltage supply circuit of throttle valve control unit – 33 FI warning lamp (MIL) flashes 3x long, 3x short Malfunction in injection valve circuit – Check the injection valve. 37 FI warning lamp (MIL) flashes 3x long, 7x short Malfunction in ignition coil circuit – Check the ignition coil.
FLASHING CODE 146 Fault Description Possible cause Action 91 FI warning lamp (MIL) flashes 9x long, 1x short Malfunction in CAN bus communication – Check CAN bus communication. 92 FI warning lamp (MIL) flashes 9x long, 2x short Malfunction in voltage supply circuit of throttle valve control unit (internal) – Check the throttle valve control unit.
CLEANING 147 CLEANING 12 Cleaning motorcycle 12.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Problem materials cause environmental damage.
CLEANING 148 Warning Danger of accidents Reduced braking due to wet or dirty brakes. – – Clean or dry dirty or wet brakes by riding and braking gently. After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes. Info The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate. – Push back the protection covers on the handlebar instruments to allow water to evaporate.
CONSERVATION FOR WINTER OPERATION 149 CONSERVATION FOR WINTER OPERATION 13 Conservation for winter operation 13.1 Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If you have ridden the vehicle on salted roads, clean it with cold water. Warm water would reinforce the effect of the salt. – Clean the motorcycle.
STORAGE 150 STORAGE 14 Storage 14.1 Info If you want to garage the motorcycle for a longer period, take the following actions. 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 can avoid long workshop waiting times at the start of the new season.
STORAGE – 151 Cover the motorcycle with a porous sheet or blanket. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust. Putting into operation after storage 14.2 – Remove the motorcycle from the work stand. ( – Recharge the battery. – Install the battery.
TECHNICAL DATA - ENGINE 152 TECHNICAL DATA - ENGINE 15 Design 1-cyliner 4-stroke engine, water-cooled Displacement 654 cm³ (39.91 cu in) Stroke 80 mm (3.15 in) Bore 102 mm (4.02 in) Compression ratio 11,8:1 Control OHC, 4 valves controlled via rocker arm, chain drive Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust 34 mm (1.34 in) Valve play, cold 0.07… 0.13 mm (0.0028… 0.
TECHNICAL DATA - ENGINE 6th gear 153 23:20 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Generator 12 V, 224 W Spark plug NGK LKAR 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 Capacity - engine oil 15.1 Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60) ( 1.20 l (1.
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 154 TECHNICAL DATA - ENGINE TIGHTENING TORQUES 16 Plug, oil bore self-tapping 9 Nm (6.6 lbf ft) Loctite® 243™ Screw, membrane fixation M3 2.5 Nm (1.84 lbf ft) Loctite® 243™ Oil jet, conrod lubrication M4 2 Nm (1.5 lbf ft) Loctite® 243™ Hose clamp, intake flange M4 1.5 Nm (1.11 lbf ft) – Screw, cover plate for oil return line M5 6 Nm (4.4 lbf ft) – Screw, breather cover on valve cover M5 3 Nm (2.
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 155 Screw, engine housing M6 10 Nm (7.4 lbf ft) – Screw, shift drum locating M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, shift lever M6 10 Nm (7.4 lbf ft) Loctite® 222 Screw, timing chain tensioning rail M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, starter motor M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, stator bracket M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, thermostat housing M6 10 Nm (7.
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 156 Screw, cylinder head M10 Tightening sequence: Tighten diagonally, beginning with the rear screw on the chain 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 Spark plug M12x1,25 17 Nm (12.5 lbf ft) – Coolant temperature sensor on cylinder head M12x1.5 12 Nm (8.9 lbf ft) – Oil drain plug with magnet M12x1,5 20 Nm (14.
TECHNICAL DATA - CHASSIS 157 TECHNICAL DATA - CHASSIS 17 Frame Lattice frame made of chrome molybdenum steel tubing, powdercoated Fork WP 4860 MXMA 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 dual-piston brake caliper, floating Rear Disc brake with single-piston brake caliper, floating Diameter of brake discs front 300 mm (11.81 in) Rear 240 mm (9.
TECHNICAL DATA - CHASSIS 158 Rear wheel gearing 15:45 Chain 5/8 x 1/4” X‑ring Steering head angle 63° Wheelbase 1,498±15 mm (58.98±0.59 in) Seat height unloaded 910 mm (35.83 in) Ground clearance unloaded 300 mm (11.81 in) Weight without fuel 138.5 kg (305.3 lb.) Maximum permissible front axle 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.
TECHNICAL DATA - CHASSIS Brake / tail light LED Licence plate lamp W2,1x9,5d 159 12 V 5W Front tire Rear tire 90/90 - 21 54 H TL Metzeler Enduro 3 Sahara 140/80 - 18 70 H TL Metzeler Enduro 3 Sahara For further information, see the Service section under: http://www.ktm.com Capacity - fuel 17.2 Fuel tank content Fuel reserve 12 l (3.2 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( 2.5 l (2.6 qt.) P.
TECHNICAL DATA - FORK 160 TECHNICAL DATA - FORK 18 Fork part number 14.18.7D.11 Fork WP 4860 MXMA Compression damping 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 length with preload spacer(s) 472 mm (18.58 in) Spring rate Weight of rider: 75… 85 kg (165… 187 lb.) 5.4 N/mm (30.8 lb/in) Air chamber length 110±20 mm (4.33±0.
TECHNICAL DATA - SHOCK ABSORBER TECHNICAL DATA - SHOCK ABSORBER 19 Shock absorber part number 15.18.7D.11 Shock absorber WP Suspension 4618 with Pro‑Lever deflector Compression damping, high-speed Comfort 2 turns Standard 1.
TECHNICAL DATA - SHOCK ABSORBER Fitted length 395 mm (15.
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 163 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 20 Remaining screws, chassis M5 4 Nm (3 lbf ft) – Spoke nipple, front wheel M5 4 Nm (3 lbf ft) – Spoke nipple, rear wheel M5 4 Nm (3 lbf ft) – Screw, exhaust heat shield M5 8 Nm (5.9 lbf ft) – Screw, electrical holder M5 3 Nm (2.2 lbf ft) – Screw, footbrake pedal foothold M5 6 Nm (4.4 lbf ft) Loctite® 243™ Screw, fuel pump M5 6 Nm (4.4 lbf ft) – Screw, fuel level indicator M5 3 Nm (2.
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 164 Screw, magnetic holder on side stand M6 10 Nm (7.4 lbf ft) Loctite® 243™ Screw, voltage regulator/rectifier M6 8 Nm (5.9 lbf ft) – Screw, SLS valve M6 4 Nm (3 lbf ft) – Screw, ignition lock M6 10 Nm (7.4 lbf ft) Loctite® 243™ Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite® 243™ Nut, manifold on cylinder head M8 25 Nm (18.4 lbf ft) Copper paste Remaining nuts, chassis M8 30 Nm (22.
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 165 Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) Loctite® 243™ Screw, side stand bracket M8 25 Nm (18.4 lbf ft) – Screw, connection lever on frame M8 30 Nm (22.1 lbf ft) – Remaining nuts, chassis M10 50 Nm (36.9 lbf ft) – Remaining screws, chassis M10 45 Nm (33.2 lbf ft) – Engine carrying screw M10 45 Nm (33.2 lbf ft) Loctite® 243™ Screw, top shock absorber M10 45 Nm (33.
SUBSTANCES 166 SUBSTANCES 21 Brake fluid DOT 4 / DOT 5.1 according to – DOT Specification – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Castrol and Motorex® products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex® – Brake Fluid DOT 5.1 Coolant Specification – Use only suitable coolant (even in countries with high temperatures).
SUBSTANCES 167 Engine oil (SAE 10W/60) according to – JASO T903 MA ( – SAE ( P. 171) P. 171) (SAE 10W/60) Specification – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex® products. Synthetic engine oil Supplier Motorex® – Cross Power 4T Fork oil (SAE 5) according to – SAE ( P.
SUBSTANCES 168 Specification – Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex® products.
AUXILIARY SUBSTANCES AUXILIARY SUBSTANCES 22 Chain cleaner Specification – KTM recommends Motorex® products. Supplier Motorex® – Chain Clean 611 Cleaning 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. Supplier Motorex® – Accu Contact High-luster polish for paint Specification – KTM recommends Motorex® products.
AUXILIARY SUBSTANCES Long-life grease Specification – KTM recommends Motorex® products. Supplier Motorex® – Long Therm 2000 Motorcycle cleaner Specification – KTM recommends Motorex® products. Supplier Motorex® – Moto Clean 900 Offroad chain spray Specification – KTM recommends Motorex® products. Supplier Motorex® – Chain Lube 622 Universal oil spray Specification – KTM recommends Motorex® products.
STANDARDS 171 STANDARDS 23 JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.
INDEX 172 A Braking Air filter fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 C INDEX Antifreeze checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 B Baggage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Battery fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 recharging . . . . . . . . .
INDEX 173 Setting/resetting TRIP 1 display Setting/resetting TRIP 2 display Speed display . . . . . . . . . . . Tachometer . . . . . . . . . . . . . Time . . . . . . . . . . . . . . . . . . . . .. .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 . 31 . 28 . 26 . 29 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX 174 Fork part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Fork protector positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Front wheel fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . .
INDEX Oil screens cleaning 175 S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 OWNER'S MANUAL Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 P Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Parking light bulb changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Passenger footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX Technical data Chassis . . . . . . . . . . . . . Chassis tightening torques Engine . . . . . . . . . . . . . Engine tightening torques Fork . . . . . . . . . . . . . . . Shock absorber . . . . . . . 176 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157-159 163-165 152-153 154-156 . . . .
*3211239en* 3211239en 03/2008 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.
