KTM 690 Enduro R Owner's Manual
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KTM 690 Enduro R Owner's Manual

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OWNER'S MANUAL
2009
690 Enduro R USA
ART. NO. 3211360en

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Summary of Contents for KTM 690 Enduro R

  • Page 1 OWNER'S MANUAL 2009 690 Enduro R USA ART. NO. 3211360en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to buy 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. We wish you great pleasure riding the vehicle! Enter the serial numbers of your vehicle below.
  • Page 4 Reproduction, even in part, is permitted 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 to the maximum possible quality of the products.

  • Page 5: Table Of Contents

    CONTENTS Setting the clock .............. 35 MEANS OF REPRESENTATION ..........7 Combination instrument - display ODO ....... 36 IMPORTANT NOTES ............... 8 Combination instrument - setting/resetting TRIP 1....36 Overview of warning labels..........12 Combination instrument - setting/resetting TRIP 2....37 VIEW OF VEHICLE..............
  • Page 6 Important maintenance work to be carried out by an Adjusting the chain tension ..........81 authorized KTM workshop. (as additional order)....61 Checking rear sprocket / engine sprocket for wear ....83 MAINTENANCE WORK ON CHASSIS AND ENGINE ....63 Checking chain wear ............
  • Page 7 CONTENTS Removing the seat ............111 Changing the engine oil and filter, cleaning the oil screens ..............142 Mounting the seat ............112 Draining the engine oil ..........143 Removing the battery ..........112 Removing the oil filter ..........144 Installing the battery ..........
  • Page 8 CONTENTS AUXILIARY SUBSTANCES........... 182 STANDARDS..............184 INDEX ................185...

  • Page 9: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical 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 specialist tools required.

  • Page 10: Important Notes

    Warranty The work prescribed in the service plan must only be carried out in an authorized KTM workshop and confirmed in the service record; oth- erwise all warranty claims will be disregarded. No warranty claim can be met for damage resulting from manipulation and/or other changes to the vehicle.
  • Page 11 Spare parts, accessories In the interests of your own safety, use only spare parts and accessories approved and/or recommended by KTM, and have these fitted in an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.
  • Page 12 IMPORTANT NOTES Environment Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such problems and conflicts do not have to occur.
  • Page 13 IMPORTANT NOTES...

  • Page 14: Overview Of Warning Labels

    IMPORTANT NOTES Overview of warning labels 800103-10...
  • Page 15 IMPORTANT NOTES Type label, Canada Type label, USA Information, emission control Information, noise emission Information, suspension setting Information, chain tension Information, fuel evaporation system Information, putting into operation 800110-01 Type label, Canada...
  • Page 16 IMPORTANT NOTES 100333-01 Type label, USA 800104-10 Information, emission control...
  • Page 17 IMPORTANT NOTES 800105-10 Information, noise emission Information, suspension setting 100337-01...
  • Page 18 IMPORTANT NOTES Information, chain tension 100338-01 Information, fuel evaporation system 100336-01 Information, putting into operation 700210-01...
  • Page 19 IMPORTANT NOTES Notes/warnings Pay close attention to the notes/warning. Info Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured. Grades of risks Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not...
  • Page 20 Noise emission warranty KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.
  • Page 21 Consumer rights Warranty claims should be directed to an authorized KTM workshop. If you are not satisfied, please contact: KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA Phone: (440) 985–3553...

  • Page 22: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left side 800106-10...
  • Page 23 VIEW OF VEHICLE Hand brake lever Clutch lever Handrail Filler cap Seat Front brake caliper Shift lever Engine number Side stand Footrest Seat release strap...

  • Page 24: View Of Vehicle, Rear Right

    VIEW OF VEHICLE View of vehicle, rear right 800107-10...
  • Page 25 VIEW OF VEHICLE Ignition/steering lock Rear mirror Light switch, flasher switch, horn button Combination instrument Emergency OFF switch, electric starter button Throttle grip Chassis number Brake caliper, rear Passenger footrest Shock absorber, rebound damping Foot brake pedal Level viewer, engine oil...

  • Page 26: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right.  100217-10 Type label Type label is located on the upper right frame tube below the seat.  100218-10...

  • Page 27: Key Number

    LOCATION OF SERIAL NUMBERS Key number 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 The engine number is stamped on the left side of the engine under the engine sprocket.

  • Page 28: Fork Part Number

    LOCATION OF SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub.  800072-10 Shock absorber part number The shock absorber part number is on the right of the shock absorber. ...

  • Page 29: Controls

    CONTROLS Clutch lever 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 The hand break lever is fitted on the right side of the handlebar. ...

  • Page 30: Light Switch

    CONTROLS Light switch 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.

  • Page 31: Horn Button

    CONTROLS Horn button The horn button is fitted on the left side of the handlebar.  Possible states • Horn button in neutral position pressed – The horn is operated in this position. • Horn button 100224-10 Emergency OFF switch The emergency OFF switch is fitted on the right side of the handlebar.

  • Page 32: Electric Starter Button

    CONTROLS Electric starter button The electric starter button is fitted on the right side of the handlebar.  Possible states • Electric starter button in basic position pressed – In this position, the electric starter is actuated. • Electric starter button 100226-10 Ignition/steering lock The ignition/steering lock...

  • Page 33: Combination Instrument

    CONTROLS Combination instrument The combination instrument is installed in front of the handlebar. The combination instrument is divided into 3 function areas. Function buttons  Indicator lamps  Display  800083-10 Combination instrument - function buttons 5.10 You can change the display mode with the M button ...

  • Page 34: Combination Instrument - Indicator Lamps

    CONTROLS Combination instrument - indicator lamps 5.11 The indicator lamps offer additional information about the operating state of the motorcy- cle. Possible states The flasher indicator lamp flashes green simultaneously with the flashers – Flasher light is switched on. Fuel level warning lamp lights up orange – Fuel level has reached the reserve mark.

  • Page 35: Combination Instrument - Display

    CONTROLS Combination instrument - display 5.12 When you switch on the ignition, all display segments light up for a second as a function test. 800083-13 LEnGth Following the display function test, the wheel circumference LEnGth is shown for one sec- ond.

  • Page 36: Combination Instrument - Speedometer

    CONTROLS Combination instrument - speedometer 5.13 The speed is shown in kilometers per hour km/h or in miles per hour mph.  800083-16 Setting kilometers or miles 5.14 Info If you change the unit, the value is retained and converted accordingly. Making the setting according to the country.

  • Page 37: Combination Instrument - Time

    CONTROLS – Switch on the ignition by turning the ignition key to position ON – Press the M button repeatedly until the Odo mode is active. – Keep the M button pressed until the display mode changes from km/h to mph or from mph to km/h.

  • Page 38: Combination Instrument - Display Odo

    CONTROLS – Switch on the ignition by turning the ignition key to position ON – Press the M button repeatedly until the Odo mode is active. – Keep the M button and the S button pressed simultaneously. The time display begins to flash. –...

  • Page 39: Combination Instrument - Setting/Resetting Trip 2

    CONTROLS – Switch on the ignition by turning the ignition key to position ON – Press the M button repeatedly until the Trip 1 mode is active. – Keep the S button pressed. The Trip 1 display is set to 0.00. 800083-19 Combination instrument - setting/resetting TRIP 2 5.19...

  • Page 40: Combination Instrument - Trip F Display

    CONTROLS Combination instrument - TRIP F display 5.20 If the fuel level drops to the reserve mark, the display automatically changes to Trip F and starts to count from 0.0, regardless of the previous display mode. Info Parallel to the Trip F display, the fuel warning light switches on. 800083-21 Combination instrument - coolant temperature indicator 5.21...

  • Page 41: Opening Filler Cap

    CONTROLS Opening filler cap 5.22 – 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 5.23...

  • Page 42: Handrails

    CONTROLS Handrails 5.24 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 5.25 The seat can be released using strap  100230-10...

  • Page 43: Passenger Footrests

    CONTROLS Passenger footrests 5.26 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 5.27 The shift lever is mounted on the left side of the engine.

  • Page 44: Foot Brake Pedal

    CONTROLS 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 5.28 The footbrake pedal is located in front of the right footrest.  The footbrake pedal operates the rear brake. 100232-10...

  • Page 45: Side Stand

    CONTROLS Side stand 5.29 The side stand is coupled with the safety electric starter system - see the riding instruc-  tions. Possible states Side stand folded out – The vehicle can be supported on the side stand. The safety •...

  • Page 46: General Tips And Hints On Putting Into Operation

    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 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 Reduced road grip with new tires. –...

  • Page 47: Running In The Engine

    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.

  • Page 48: Loading The Vehicle

    GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION Loading the vehicle 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, driver and passenger with protective clothing and helmet, baggage. Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack.
  • Page 49 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION Warning Danger of accidents Unstable handling characteristics due to slipped baggage. – Check the way your baggage is fixed regularly. Warning Danger of burns A hot exhaust system can burn baggage. – Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system. –...

  • Page 50: Riding Instructions

    RIDING INSTRUCTIONS Checks before putting into operation 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. ( p.

  • Page 51: Starting

    RIDING INSTRUCTIONS Starting 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 without an effective exhaust extraction system.

  • Page 52: Starting Up

    RIDING INSTRUCTIONS – Turn the emergency OFF switch to the position – Switch on the ignition by turning the ignition key to position ON After you switch on the ignition, you can hear the fuel pump working for about 2 seconds.

  • Page 53: Shifting, Riding

    RIDING INSTRUCTIONS Shifting, riding 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. –...
  • Page 54 RIDING INSTRUCTIONS 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. –...
  • Page 55 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. – When conditions allow (incline, road situation, etc.), you can shift into a higher gear.

  • Page 56: Braking

    Clean or dry dirty or wet brakes by riding and braking gently. Warning Danger of accidents Reduced braking caused by spongy pressure point of front or rear brake. – Have the brake system checked in an authorized KTM workshop, and do not ride any further.

  • Page 57: Stopping, Parking

    RIDING INSTRUCTIONS 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.
  • Page 58 RIDING INSTRUCTIONS 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 The parked vehicle can roll away or fall over.

  • Page 59: Refueling

    RIDING INSTRUCTIONS – Lock the steering by turning the handlebar fully to the left, pressing down the ignition key to position and turning it to position To make the steering lock engage more easily, move the handlebar a little to the left and right. Remove the ignition key. Refueling Danger Fire hazard Fuel can easily catch fire.
  • Page 60 RIDING INSTRUCTIONS – Switch off engine. – Open the filler cap. ( p. 39) – Fill the fuel tank with fuel up to measurement  Guideline Measurement of 20 mm (0.79 in)  Total fuel tank 12 l (3.2 US gal) Super unleaded (ROZ 95 / RON 95 / capacity, approx.

  • Page 61: Service Plan

    SERVICE PLAN Important maintenance work to be carried out by an authorized KTM workshop. K10N K50A K100A Engine • • • • • Change the engine oil and filter, clean the oil screens. p. 142) • • Check and adjust valve clearance.
  • Page 62 SERVICE PLAN K10N K50A K100A Attachments Check the headlamp setting. ( p. 127) • • • • • Check the functioning of the electrical equipment. • • • • • Check screws and nuts for tightness. • • • • •...

  • Page 63: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop. (As Additional Order)

    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 Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) K100A Carry out a complete fork service. •...
  • Page 64 SERVICE PLAN J1A: annually J2A: every 2 years...

  • Page 65: Maintenance Work On Chassis And Engine

    MAINTENANCE WORK ON CHASSIS AND ENGINE Jacking up the motorcycle Note Danger of damage The parked vehicle can roll away or fall 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.

  • Page 66: Fork/Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE Fork/shock absorber 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 .

  • Page 67: Adjusting The Rebound Damping Of The Fork

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline 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.

  • Page 68: Compression Damping Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline 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.
  • Page 69 MAINTENANCE WORK ON CHASSIS AND ENGINE Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. – Turn adjusting screw clockwise with a screwdriver as far as the last perceptible click.  Info Do not loosen nut ...

  • Page 70: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the high-speed compression damping of the shock absorber 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- nance on it yourself.

  • Page 71: Adjusting The Rebound Damping Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn adjusting screw clockwise as far as it will go using an open end wrench.  Info Do not loosen nut  – Turn back counterclockwise by the number of turns corresponding to the shock absorber type.

  • Page 72: Measuring The Unloaded Rear Wheel Sag

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn adjusting screw clockwise to the last perceptible click.  – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks 100247-10...

  • Page 73: Checking The Static Sag Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the static sag of the shock absorber 9.11 – Measure distance of rear wheel unloaded. ( p. 70)  – Ask someone to help you by holding the motorcycle upright. – Measure the distance between the rear axle and the fixed point again. 0 0 A –...

  • Page 74: Checking The Riding Sag Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the riding sag of the shock absorber 9.12 – Measure distance of rear wheel unloaded. ( p. 70)  – With another person holding the motorcycle, the rider sits on the saddle with full protective clothing in a normal sitting position (feet on footrests) and bounces up and down a few times until the rear suspension levels out.

  • Page 75: Bleeding The Fork Legs

    MAINTENANCE WORK ON CHASSIS AND ENGINE Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. – Remove the shock absorber. – After removing the shock absorber, clean it thoroughly. –...

  • Page 76: Cleaning The Dust Boots Of The Fork Legs

    MAINTENANCE WORK ON CHASSIS AND ENGINE – 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. 800091-10 Cleaning the dust boots of the fork legs 9.15 –...

  • Page 77: Loosening The Fork Protection

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove excess oil. – Position the fork protection. ( p. 75) – Remove the motorcycle from the work stand. ( p. 63) Loosening the fork protection 9.16 – Remove screws and take off clamp. ...

  • Page 78: Checking The Steering Head Bearing Play

    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.

  • Page 79: Adjusting The Play Of The Steering Head Bearing

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the play of the steering head bearing 9.19 – Jack up the motorcycle. ( p. 63) – Loosen screw . Remove screw   – Loosen and retighten screw  Guideline Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft) –...

  • Page 80: Handlebar Position

    MAINTENANCE WORK ON CHASSIS AND ENGINE Handlebar position 9.20 On the upper triple clamp, there are 2 holes at a distance to each other.  Distance between holes 15 mm (0.59 in)  The holes on the handlebar support are placed at a distance from the center.

  • Page 81: Checking Chain Dirt

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the handlebar. Info Make sure cables and wiring are positioned correctly. – Position the handlebar clamp. Fit and evenly tighten the four screws  Guideline Screw, handlebar clamp 20 Nm Loctite ® 243™...

  • Page 82: Checking The Chain Tension

    MAINTENANCE WORK ON CHASSIS AND ENGINE Info The service life of the chain depends largely on its maintenance. – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( p.

  • Page 83: Adjusting The Chain Tension

    MAINTENANCE WORK ON CHASSIS AND ENGINE – 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.
  • Page 84 MAINTENANCE WORK ON CHASSIS AND ENGINE – Check the chain tension. ( p. 80) – Loosen nut  – Loosen nuts  – Adjust the chain tension by turning adjusting screws on the left and right.  Guideline Chain tension 5 mm (0.2 in) Turn the left and right adjusting screws so that the markings on the left and right...

  • Page 85: Checking Rear Sprocket / Engine Sprocket For Wear

    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. 100132-10 –...

  • Page 86: Checking Chain Wear

    New chains wear out faster on old, worn sprockets. 1 2 3 16 17 18 For safety reasons, the chain has no chain joint. Always have the chain 400409-10 changed in an authorized KTM workshop, where the necessary tool is available.

  • Page 87: Adjusting Chain Guide

      Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 100299-10 Checking the brake discs 9.29 Warning Danger of accidents Reduced braking due to worn brake discs. – Worn brake discs should be replaced immediately in an authorized KTM workshop.

  • Page 88: Checking The Free Play Of Hand Brake Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Check the thickness of the front and rear brake discs in several places to ensure that it conforms to measurement  Info Wear reduces the thickness of the brake disc at the contact surface of the ...

  • Page 89: Adjusting Free Travel Of Handbrake Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Push the hand brake to the handlebar and check free play  ≥ 3 mm (≥ 0.12 in) Free play of hand brake lever » If the free travel does not meet specifications: –...

  • Page 90: Checking The Front Brake Fluid Level

    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. – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
  • Page 91 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. Warning Environmental hazard Hazardous substances cause environmental damage. –...

  • Page 92: Checking The Front Brake Linings

    9.34 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...

  • Page 93: Changing The Front Brake Linings

    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 Danger of accidents Reduced braking due to oil or grease on the brake discs.
  • Page 94 Brake 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 considerably from the original KTM brake lin- ings.
  • Page 95 MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove the safety clip , knock the pin out to the right, and remove the brake lin-   ings. – Clean brake caliper and brake caliper support. 400418-11 – Check that leaf spring in the brake caliper and sliding plate in the brake caliper ...

  • Page 96: Checking Free Play Of Foot Brake Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Add brake fluid level to  Guideline Level 5 mm (0.2 in)  Brake fluid DOT 4 / DOT 5.1 ( p. 178) – Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water.

  • Page 97: Adjusting Basic Position Of Footbrake Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting basic position of footbrake lever 9.37 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.

  • Page 98: Checking Rear Brake Fluid Level

    KTM workshop, and do not ride any further. 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. –...
  • Page 99 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. Warning Environmental hazard Hazardous substances cause environmental damage. –...

  • Page 100: Checking The Rear Brake Linings

    If there is wear or tearing: – Change the rear brake linings. p. 98) 100260-10 Changing the rear brake linings 9.41 Warning Danger of accidents Improper brake maintenance and repair. – Always have your brake system maintained and repaired in an authorized KTM workshop.
  • Page 101 Brake 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 considerably from the original KTM brake lin- ings.
  • Page 102 MAINTENANCE WORK ON CHASSIS AND ENGINE – Stand the vehicle upright. – Remove the screw cap with the membrane   – Press the brake caliper by hand on to the brake disc in order to press back the brake piston.

  • Page 103: Removing The Front Wheel

    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. –...
  • Page 104 MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screw  – Loosen screw  800079-10 – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. 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.

  • Page 105: Installing The Front Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the front wheel 9.43 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. –...

  • Page 106: Removing Rear Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Fully tighten the screws  Guideline Screw, fork stub 15 Nm (11.1 lbf ft) Removing rear wheel 9.44 – Jack up the motorcycle. ( p. 63) – Press the brake caliper by hand on to the brake disc in order to press back the brake piston.

  • Page 107: Installing The Rear Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the rear wheel 9.45 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.

  • Page 108: Checking The Rear Hub Rubber Dampers

    MAINTENANCE WORK ON CHASSIS AND ENGINE – 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 correctly aligned, the markings on the left and right chain adjusters must be in the same position relative to the reference marks ...

  • Page 109: Checking The Tire Condition

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Check the 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 –...
  • Page 110 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 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 Reduced road grip with new tires. –...

  • Page 111: Checking The Tire Air Pressure

    DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture. KTM recommends that the tires are changed regardless of the actual wear, at the latest after 5 years.

  • Page 112: Checking Spoke Tension

    Correct tire pressure. – Mount dust cap. Checking spoke tension 9.49 Warning Danger of accidents Unstable riding behavior due to loose spokes. – If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop.

  • Page 113: Removing The Seat

    MAINTENANCE WORK ON CHASSIS AND ENGINE Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time. If the spokes are too tight, they can break due to local overload. Check the spoke tension regularly, especially on a new motorcycle. –...

  • Page 114: Mounting The Seat

    MAINTENANCE WORK ON CHASSIS AND ENGINE Mounting the seat 9.51 – 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 ...

  • Page 115: Installing The Battery

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Disconnect the negative (minus) cable of the battery. – Pull off the plug connector upwards.  – Remove screws  – Pull the retaining bracket of the battery forward and remove it.  –...

  • Page 116: Recharging The Battery

    – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 117 MAINTENANCE WORK ON CHASSIS AND ENGINE 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.

  • Page 118: Changing The Main Fuse

    MAINTENANCE WORK ON CHASSIS AND ENGINE – 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 bat- tery, and to test the generator. With this device, you cannot overcharge the battery. Info Never remove lid ...
  • Page 119 – Insert the new main fuse. Fuse (58011109130) ( p. 170) Info If the new fuse burns out, contact an authorized KTM workshop. A reserve fuse is located in the starter relay.  – Check that the electrical equipment is functioning properly.

  • Page 120: Changing The Fuses Of Power Consumers

    MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the fuses of power consumers 9.56 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. –...
  • Page 121 MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove the defective fuse. Guideline Fuse 1 - 10A - ignition, combination instrument, alarm system (optional) Fuse 2 - 10A - clock, ignition (EFI control unit) Fuse 3 - 10A - throttle valve control unit Fuse 4 - 10A - fuel pump Fuse 5 - 10A - radiator fan Fuse 6 - 10A - horn, brake light, flasher light, alarm system (optional)

  • Page 122: Adjusting The Engine Characteristic

    170) Fuse (75011088015) ( p. 170) Info If the new fuse burns out, contact an authorized KTM workshop. Put a new spare fuse in the fuse box for future use if needed. – Checking the function of power consumers.
  • Page 123 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. 100237-10 – Turn the adjusting wheel until the desired digit is next to marking ...

  • Page 124: Headlight Mask, Removing With Headlight

    MAINTENANCE WORK ON CHASSIS AND ENGINE Headlight mask, removing with headlight 9.58 – Switch off all power consumers and switch off the engine. – Remove screw and take off the clamp.  – Release rubber band . Slide the headlight mask upward and tilt it forward. ...

  • Page 125: Installing The Headlight Mask With The Headlight

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Disconnect the electrical plug-in connection and remove the headlight mask with the  headlight. 800102-10 Installing the headlight mask with the headlight 9.59 – Connect the electrical plug-in connection  800102-11...

  • Page 126: Changing The Headlight Bulb

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the headlight mask and fix it with rubber band  Info Make sure that the holding lugs engage in the fender. – Position the brake line and cable harness. Position the clamp, and mount and tighten screw ...

  • Page 127: Changing The Parking Light Bulb

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Pull off connectors    – Take off rubber cap of the headlight bulb.  800098-10 – Turn holder about 30° counterclockwise and remove it.  – Remove headlight bulb. – Insert a headlight bulb in the holder. Headlight (BA20d) ( p.

  • Page 128: Changing The Flasher Bulb

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Pull bulb socket out of the reflector.  – Pull parking light bulb out of the bulb socket.  – Insert a new parking light bulb in the bulb socket. Parking light (W2.1x9.5d) ( p.

  • Page 129: Check The Headlamp Setting

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Insert the screw and turn it counterclockwise first until it engages in the thread. Tighten the screw slightly. – Check the flasher system function. Check the headlamp setting 9.63 – On a light-colored wall behind a horizontal area, make a mark as high as the center of 0 0 A the low beam headlight.

  • Page 130: Removing The Air Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Loosen screw  – Adjust the light range by swiveling the headlight. Guideline For a motorcycle with rider, the light/dark boundary must be exactly on the lower mark (made in: Checking headlight adjustment). Info If you have a heavy payload, you will need to correct the headlight range.

  • Page 131: Installing The Air Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE 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. –...

  • Page 132: Cooling System

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount and tighten screws  Guideline Screw, air filter box top 2 Nm (1.5 lbf ft) – Mount the seat. ( p. 112) 100285-11 Cooling system 9.67 The water pump in the engine forces the coolant to flow. ...

  • Page 133: Checking The Antifreeze And Coolant Level

    MAINTENANCE WORK ON CHASSIS AND ENGINE 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 the cooling effect. Dirty cooling fins also reduce the cooling effect.
  • Page 134 MAINTENANCE WORK ON CHASSIS AND ENGINE 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) »...

  • Page 135: Checking The Coolant Level

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Screw off the radiator cap  – Check antifreeze of coolant. −25… −45 °C (−13… −49 °F) » If the antifreeze of the coolant does not meet specifications: – Correct the antifreeze of the coolant. –...
  • Page 136 MAINTENANCE WORK ON CHASSIS AND ENGINE 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 con- tact 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.

  • Page 137: Draining The Coolant

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Screw off the radiator cap and check the coolant level in the radiator.  The radiator must be completely filled. » If the coolant level does not meet specifications: – Rectify the coolant level and find out the cause of the loss. Alternative 1 Coolant ( p.

  • Page 138: Filling The Cooling System

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Stand the motorcycle upright. – Place a suitable container under the engine. – Remove screw . Remove the radiator cap.  – Completely drain the coolant. – Mount the screw with a new seal ring and tighten it. ...
  • Page 139 MAINTENANCE WORK ON CHASSIS AND ENGINE – Refill the coolant. Alternative 1 Coolant ( p. 178) Alternative 2 Coolant (mixed ready to use) ( p. 178) – Fill the radiator completely with coolant. Mount radiator cap  600619-10 – Remove the cap from compensating tank and add coolant to the level shown in the ...

  • Page 140: Adjusting Basic Position Of Clutch Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting basic position of clutch lever 9.72 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.

  • Page 141: Checking The Play In The Gas Bowden Cable

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screws  – Remove cover with membrane   – Check the fluid level. Fluid level under top level of container 4 mm (0.16 in) » If the level of the coolant does not meet specifications: –...

  • Page 142: Adjusting The Play In The Gas Bowden Cable

    Adjusting the play in the gas Bowden cable 9.75 – Move the handlebar to the straight-ahead position. – Use the KTM diagnostics tool to set the throttle stepper motor to the neutral position. – Loosen counter nut  – Set the play in the gas Bowden cable by turning the adjusting screw ...

  • Page 143: Removing The Engine Guard

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the engine guard 9.76 – 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. 100198-10 Installing the engine guard 9.77...

  • Page 144: Checking The Engine Oil Level

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the engine oil level 9.78 Info The engine oil level must be checked when the engine is warm. – Stand the motorcycle upright on a horizontal surface. Condition The engine is at operating temperature. –...

  • Page 145: Draining The Engine Oil

    MAINTENANCE WORK ON CHASSIS AND ENGINE Draining the engine oil 9.80 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 Hazardous substances cause environmental damage.

  • Page 146: Removing The Oil Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Thoroughly clean the oil drain plug with a magnet. – Mount the oil drain plug with the magnet and seal ring and tighten it. Guideline Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) 100201-01 Removing the oil filter...
  • Page 147 MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screws . Remove the oil filter cover with the O-ring.   – Pull oil filter out of the oil filter housing.  Circlip pliers reverse (51012011000) 100202-10 – Remove screws . Remove oil filter with the O-ring.

  • Page 148: Installing The Oil Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the oil filter 9.82 – Insert oil filters   – Oil the O-rings of the oil filter cover. Fit the oil filter covers   – Mount and tighten the screws. Guideline Screw, oil filter cover 6 Nm (4.4 lbf ft) 100204-10...
  • Page 149 MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove plug with oil screen and the O-rings.   100205-10 – Remove plug with oil screen and the O-rings.   – Completely drain the remaining engine oil. – Thoroughly clean the parts and sealing area. 100206-10 –...

  • Page 150: Filling Up With Engine Oil

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Position oil screen with the O-rings.  – Mount and tighten plug with the O-ring.  Guideline Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) 100208-10 Filling up with engine oil 9.84 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine.

  • Page 151: Adding Engine Oil

    MAINTENANCE WORK ON CHASSIS AND ENGINE 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 without an effective exhaust extraction system.
  • Page 152 MAINTENANCE WORK ON CHASSIS AND ENGINE 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 without an effective exhaust extraction system.

  • Page 153: Troubleshooting

    Reconnect coupling of fuel hose connection. connected – Socket connector of cable harness oxi- Clean socket connector and treat it with contact dized spray. – Defect in fuel injection system Read the error memory with the KTM diagnostics tool and correct the fault.
  • Page 154 – 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. – Engine overheats. Too little coolant in cooling system Check the cooling system for leakage.
  • Page 155 TROUBLESHOOTING Faults Possible cause Action – Headlight and parking light not func- Fuse 7 blown Change the fuses of power consumers. tioning p. 118) – Flasher light, brake light and horn not Fuse 6 blown Change the fuses of power consumers. functioning p.

  • Page 156: Flashing Code

    FLASHING CODE Flashing code FI of warning lamp 02 FI warning lamp (MIL) flashes briefly 2x (MIL) Possible cause Malfunction in ignition pulse generator circuit Flashing code FI of warning lamp 06 FI warning lamp (MIL) flashes briefly 6x (MIL) Possible cause Input signal of throttle valve sensor circuit A too low Input signal of throttle valve sensor circuit A too high...
  • Page 157 FLASHING CODE Flashing code FI of warning lamp 13 FI warning lamp (MIL) flashes 1x long, 3x short (MIL) Possible cause Input signal from intake air temperature sensor too low Input signal from intake air temperature sensor too high Flashing code FI of warning lamp 14 FI warning lamp (MIL) flashes 1x long, 4x short (MIL) Possible cause...
  • Page 158 FLASHING CODE Flashing code FI of warning lamp 26 FI warning lamp (MIL) flashes 2x long, 6x short (MIL) Possible cause Malfunction in circuit of Hall sensor throttle valve control Flashing code FI of warning lamp 27 FI warning lamp (MIL) flashes 2x long, 7x short (MIL) Possible cause Malfunction in the EPT control unit power supply circuit...
  • Page 159 FLASHING CODE Flashing code FI of warning lamp 54 FI warning lamp (MIL) flashes 5x long, 4x short (MIL) Possible cause Interruption/short-circuit to ground in secondary air valve circuit Flashing code FI of warning lamp 58 FI warning lamp (MIL) flashes 5x long, 8x short (MIL) Possible cause Malfunction of release of throttle stepper motor in EPT mode...
  • Page 160 FLASHING CODE Flashing code FI of warning lamp 92 FI warning lamp (MIL) flashes 9x long, 2x short (MIL) Possible cause Malfunction in voltage supply circuit of EPT control unit (internal)

  • Page 161: Cleaning

    CLEANING 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, plug connectors, Bowden cables and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 162 CLEANING 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.

  • Page 163: Conserving For Winter Operation

    CONSERVING FOR WINTER OPERATION 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. –...

  • Page 164: Storage

    Storage temperature of battery without direct sunshine. 0… 35 °C (32… 95 °F) – The storage place should be dry and not subject to large temperature differences. Info KTM recommends jacking up the motorcycle. – Jack up the motorcycle. ( p. 63)

  • Page 165: Putting Into Operation After Storage

    STORAGE – 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.

  • Page 166: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 1-cylinder 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)

  • Page 167: Capacity- Engine Oil

    TECHNICAL DATA - ENGINE 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...

  • Page 168: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Oil hole plug self-tapping 9 Nm (6.6 lbf ft) Loctite 243™ ® Screw, membrane fixation 2.5 Nm (1.84 lbf ft) Loctite 243™ – Hose clamp, intake flange 1.5 Nm (1.11 lbf ft) ® Oil jet, conrod lubrication 2 Nm (1.5 lbf ft) Loctite...
  • Page 169 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Screw, locking lever 10 Nm (7.4 lbf ft) Loctite 243™ – Screw, rocker arm shaft 12 Nm (8.9 lbf ft) ® Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite 243™ ® Screw, shift lever 10 Nm (7.4 lbf ft) Loctite...
  • Page 170 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Oil hole plug M10x1 15 Nm (11.1 lbf ft) Loctite 243™ – Plug, drain hole of water pump M10x1 15 Nm (11.1 lbf ft) – Plug, oil bore for oil radiator M10x1 15 Nm (11.1 lbf ft) –...

  • Page 171: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS Frame Lattice frame made of chrome molybdenum steel tubing, powder- coated Fork WP Suspension 4860 MXMA Shock absorber WP Suspension 4618 with Pro‑Lever deflector Suspension travel Front 275 mm (10.83 in) Rear 275 mm (10.83 in) Brake system Front Disc brake with dual-piston brake caliper, floating...

  • Page 172: Lighting Equipment

    TECHNICAL DATA - CHASSIS Secondary drive ratio 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 930 mm (36.61 in) Ground clearance unloaded 320 mm (12.6 in) Weight without fuel approx. 138.5 kg (305.3 lb.) Maximum permissible front axle load 150 kg (331 lb.)

  • Page 173: Tires

    90/90 - 21 M/C 54R TT 140/80 - 18 M/C 70R TT Pirelli MT 21 RALLYCROSS Pirelli MT 21 RALLYCROSS Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 17.3 Total fuel tank capacity, approx. 12 l (3.2 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p.

  • Page 174: Technical Data - Fork

    TECHNICAL DATA - FORK Fork part number 14.18.7E.41 Fork WP Suspension 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) 495 mm (19.49 in)

  • Page 175: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 15.18.7E.41 Shock absorber WP Suspension 4618 with Pro‑Lever deflector Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1 turn Full payload 1 turn Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport...
  • Page 176 TECHNICAL DATA - SHOCK ABSORBER Shock absorber oil ( p. 180) SAE 2.5...

  • Page 177: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw, license plate holder, bottom 3 Nm (2.2 lbf ft) – Screw, SLS valve 2 Nm (1.5 lbf ft) – Spoke nipple, front wheel M4.5 5 Nm (3.7 lbf ft) – Remaining screws, chassis 4 Nm (3 lbf ft) –...
  • Page 178 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ® Screw, magnetic holder on side stand 10 Nm (7.4 lbf ft) Loctite 243™ – Screw, radiator bracket 5 Nm (3.7 lbf ft) ® Screw, rear brake disc 14 Nm (10.3 lbf ft) Loctite 243™...
  • Page 179 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ® Screw, steering stem 20 Nm (14.8 lbf ft) Loctite 243™ – Screw, top triple clamp 17 Nm (12.5 lbf ft) – Upper fuel tank screw 20 Nm (14.8 lbf ft) ® Engine carrying screw 45 Nm (33.2 lbf ft) Loctite 243™...

  • Page 180: Substances

    – Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 181 184) (SAE 10W/60) – KTM LC4 2007+ Guideline – 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 –...
  • Page 182 – 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 recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75 Shock absorber oil (SAE 2.5) (50180342S1)
  • Page 183 SUBSTANCES Super unleaded (ROZ 95 / RON 95 / PON 91) According to – DIN EN 228 (ROZ 95 / RON 95 / PON 91)

  • Page 184: Auxiliary Substances

    AUXILIARY SUBSTANCES 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...
  • Page 185 AUXILIARY SUBSTANCES Long-life grease Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Fett 2000 Motorcycle cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Moto Clean 900 Offroad chain spray Specification – ® KTM recommends Motorex products.

  • Page 186: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, 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.

  • Page 187: Index

    INDEX Brakes ........54 Braking .
  • Page 188 INDEX setting kilometers or miles ..... . . 34 Engine oil speed display ....... . 34 adding .
  • Page 189 INDEX Fork protector Indicator lamps ....... . . 32 positioning .
  • Page 190 INDEX Parking light bulb Seat release ........40 changing .
  • Page 191 INDEX Technical data chassis ....... 169-171 chassis tightening torques ....175-177 engine .
  • Page 192 *3211360en* 3211360en 11/2008 Photo: Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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