TABLE OF CONTENTS Adjusting the rebound damping of the shock TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 absorber............38 Symbols used ........... 5 Measuring the unloaded rear wheel sag ..... 38 Formats used............ 5 Checking the static sag of the shock absorber ..38 SAFETY ADVICE............
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TABLE OF CONTENTS 13.7.8 Checking the chain, rear sprocket, engine 17.3.9 Removing thermostat ........ 112 sprocket, and chain guide......78 17.3.10 Setting engine to ignition top dead center ... 112 13.7.9 Cleaning the chain ........80 17.3.11 Removing water pump wheel...... 113 13.7.10 Checking the rear hub rubber dampers..
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TABLE OF CONTENTS 17.4.30 Checking the clutch ........138 20 LUBRICATION SYSTEM..........169 17.4.31 Preassembling the antihopping clutch..140 20.1 Oil circuit............. 169 17.4.32 Checking shift mechanism......141 20.2 Checking the engine oil level......169 17.4.33 Preassembling shift shaft ......141 20.3 Checking the engine oil pressure ....
MEANS OF REPRESENTATION Symbols used The meaning of specific symbols is described below. 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). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips.
Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle. This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available. Safety advice A number of safety instructions need to be followed to operate the vehicle safely.
Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle.
SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. 601764-10 Type label The type label is located on the right side of the frame. 601765-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.
MOTORCYCLE Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle using the underride guard under the motorcycle. The wheels must no longer touch the ground.
MOTORCYCLE Removing the motorcycle from the work stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Secure the motorcycle against falling over. – Remove the work stand and lean the vehicle on the side stand. 300201-10 –...
MOTORCYCLE Info Do not press the electric starter button until the combination instrument function check is finished. When starting, DO NOT open the throttle. If you open the throttle during the starting procedure, fuel is not injected by the engine management system and the engine cannot start.
FORK, TRIPLE CLAMP Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn adjusting screws clockwise all the way. Info The adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs.
FORK, TRIPLE CLAMP Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 10) – Loosen the fork protection. ( p. 14) Main work – Push dust boot of both fork legs downwards. Info The dust boots remove dust and coarse dirt particles from the inside fork tubes.
FORK, TRIPLE CLAMP Removing the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 10) – Tie down the rear of the vehicle. Main work – Remove screws – Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc.
FORK, TRIPLE CLAMP – Remove screws . Remove the fork protector from above. 202027-10 Installing the fork legs – Slide on the fork protector from above and position it. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 202027-11 –...
FORK, TRIPLE CLAMP Warning Danger of accidents Reduced braking efficiency 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. – Clean screw and the wheel spindle.
FORK, TRIPLE CLAMP 6.10 Disassembling the fork legs Info The steps are identical for both fork legs. Condition The fork legs are disassembled. – Note down the present state of rebound damping and compression damping – Completely open the adjusters of the rebound and compression damping. 201470-10 –...
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FORK, TRIPLE CLAMP – Clamp the special tool in the vise. Loosen screw cover 200647-12 – Remove screw cover with preload spacers – Remove adjusting tube 200648-12 – Pull the spring down. Remove the special tool. – Remove the spring. 200649-01 –...
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FORK, TRIPLE CLAMP – Remove the cartridge. 200653-01 – Remove dust boot 200735-10 – Remove lock ring Info The lock ring has a beveled end where a screwdriver can be applied. 200656-01 – Warm up the outer tube in area of the lower sliding bushings.
FORK, TRIPLE CLAMP 6.11 Disassembling the cartridge Info The steps are identical for both fork legs. Preparatory work – Disassemble the fork legs. ( p. 18) Main work – Degrease the piston rod. – Clamp the piston rod with the special tool. Clamping stand (T14016S) ( p.
FORK, TRIPLE CLAMP – Degrease the piston rod. – Clamp the piston rod with the special tool. Clamping stand (T14016S) ( p. 224) 200697-10 – Remove nut – Remove shim stack completely. 200698-11 – Remove the piston. – Completely remove shim stack 200699-11 –...
FORK, TRIPLE CLAMP Main work – Clamp the tap compression in a bench vise using soft jaws. – Remove nut – Remove the spring. – Remove washer 201482-10 – Remove piston – Remove shim stack 201483-10 – Extract the tap compression. –...
FORK, TRIPLE CLAMP – Measure the run-out of the inner tube. ≤ 0.20 mm (≤ 0.0079 in) Run-out of inner tube » If the measured value is greater than the specified value: – Replace the inner tube. 200685-10 – Check the outer tube for damage. »...
FORK, TRIPLE CLAMP – Clamp the tap compression in a bench vise using soft jaws. – Mount shim stack Info Mount the smaller shims below. – Mount pistons with O-ring. Info The side with the largest inside diameter faces upward. 201485-10 –...
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FORK, TRIPLE CLAMP – Mount piston with the piston ring. Info The side with the largest inside diameter faces downward. – Mount shim stack Info Align the triangular plate exactly with the piston opening. – Mount and tighten nut Guideline Tap rebound nut M6x0.5 5 Nm (3.7 lbf ft)
FORK, TRIPLE CLAMP – Screw on fluid barrier as far as it will go. Info The fluid barrier must be tightened as much as possible. Do not use tools. 200746-12 6.16 Assembling the fork legs Info The steps are identical for both fork legs. Preparatory work –...
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FORK, TRIPLE CLAMP – Push on the lower sliding bushing – Mount the upper sliding bushing Info Without using a tool, carefully pull the stack apart by hand. 200671-10 – Heat up the outer tube in area of the lower sliding bushings. Guideline 50 °C (122 °F) –...
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FORK, TRIPLE CLAMP Info The special tool must be used to prevent the adjusting tube from being lifted and thus to prevent oil from reaching the piston rod. – Lubricate the O-ring. Lubricant (T158) ( p. 212) – Mount and tighten compression adjuster Guideline Compression adjuster M14x1...
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FORK, TRIPLE CLAMP – Clamp the special tool in the vise. – Grease the thread of the piston rod. Lubricant (T159) ( p. 212) – Grease the upper edge of the piston rod. Lubricant (T158) ( p. 212) – Screw the screw cover with the preload spacers on to the piston rod. Info 201477-10 The screw cover must be screwed to the stop before the piston rod starts...
FORK, TRIPLE CLAMP Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seri- ously alter the vehicle's ride behavior. – Extreme modifications to the adjustment of the suspension compo- nents can cause a serious deterioration in the handling characteris- tics and overload some components.
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FORK, TRIPLE CLAMP Guideline Screw, steering stem 20 Nm (14.8 lbf ft) Finishing work – Check the steering head bearing play. ( p. 31) – Remove the motorcycle from the lift stand. ( p. 10)
HANDLEBAR, CONTROLS Handlebar position 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. Distance between holes 3.5 mm (0.138 in)
33) Main work – Move the handlebar to the straight-ahead position. – Use the KTM diagnostics tool to set the throttle stepper motor to the neutral posi- tion. – Loosen lock nut – Set the play in the throttle cable by turning adjusting screw...
FRAME Removing the engine guard – Remove screws on the left and right. – Pull the engine guard forward out of the holders and set it down. 202021-10 Installing the engine guard – Slide the engine guard into holders at the rear. –...
SHOCK ABSORBER, SWINGARM Adjusting the high-speed compression damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Info The high-speed setting takes effect during the fast compression of the shock absorber. –...
SHOCK ABSORBER, SWINGARM Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. – Turn adjusting screw clockwise up to the last perceptible click.
SHOCK ABSORBER, SWINGARM Checking the riding sag of the shock absorber – Measure distance of rear wheel unloaded. ( p. 38) – With another person holding the motorcycle, the rider, wearing full protective cloth- ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up 0 0 A and down a few times.
SHOCK ABSORBER, SWINGARM Adjusting the riding sag Preparatory work – Raise the motorcycle with the work stand. ( p. 10) – Remove the seat. ( p. 62) – Take off the side cover. ( p. 63) – Remove the shock absorber. ( p.
SHOCK ABSORBER, SWINGARM – Lift the rear fairing. – Mount and tighten screws Guideline Screw, main silencer holder on fuel 25 Nm tank (18.4 lbf ft) 202037-13 – Mount and tighten screws Guideline Screw, side cover 5 Nm (3.7 lbf ft) 202036-13 Finishing work –...
SHOCK ABSORBER, SWINGARM 9.12 Removing the spring Condition The shock absorber has been removed. – Clamp the shock absorber in the vise using soft jaws for protection. – Measure and note spring length in preloaded state. – Loosen retaining ring and the adjusting ring with the special tool.
SHOCK ABSORBER, SWINGARM – Remove screw . Drain the oil. 201277-10 – Remove the piston rod. Drain the remaining oil. 201278-10 – Remove compression adjuster . Remove the spring, sleeve, and piston. 201279-10 9.14 Disassembling the piston rod Preparatory work –...
SHOCK ABSORBER, SWINGARM – Remove supporting plate and rebound shim stack together with piston Info Thread the rebound shim set on a screwdriver and set the parts down together. 300541-10 – Remove compression shim stack with supporting plate Info Thread the compression shim stack on a screwdriver and set the parts down together.
SHOCK ABSORBER, SWINGARM – Measure the diameter of the piston rod. Piston rod ≥ 17.95 mm (≥ 0.7067 in) Diameter » If the specification is not reached: – Change the piston rod. – Measure the run-out of the piston rod. Piston rod 300554-10 ≤...
SHOCK ABSORBER, SWINGARM – Remove lock rings on both sides. 200579-10 – Place special tool underneath and press out the heim joint with special tool Pressing tool (T1207S) ( p. 223) 200580-10 9.17 Installing the heim joint – Place special tool underneath and press in the heim joint as far as the center using special tool Pressing tool (T1206) (...
SHOCK ABSORBER, SWINGARM 9.18 Assembling the piston rod Preparatory work – Check the damper. ( p. 45) Main work – Clamp the piston rod with the heim joint in a vise. Guideline Use soft jaws. – Mount rubber buffer and locking cap 300543-11 –...
SHOCK ABSORBER, SWINGARM – Mount and tighten nut Guideline Piston rod nut M12x1 40 Nm (29.5 lbf ft) 300540-11 9.19 Assembling the damper Preparatory work – Check the damper. ( p. 45) – Assemble the piston rod. ( p. 48) Main work –...
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SHOCK ABSORBER, SWINGARM – Grease O-ring of the seal ring retainer. Lubricant (T158) ( p. 212) – Mount the piston rod carefully. 201278-11 – Install the seal ring bearer and push it under the ring groove. – Mount lock ring Info Do not scratch the inner surface.
SHOCK ABSORBER, SWINGARM Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seri- ously alter the vehicle's ride behavior. – Extreme modifications to the adjustment of the suspension compo- nents can cause a serious deterioration in the handling characteris- tics and overload some components.
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SHOCK ABSORBER, SWINGARM – Measure distance between the floating piston and reservoir hole with the special tool. Depth micrometer (T107S) ( p. 223) The floating piston is positioned all the way at the bottom. 201285-10 – When the vacuum pressure gauge reaches the specified value, turn the Oil reser- voir control lever to Equalize pressure.
SHOCK ABSORBER, SWINGARM – When the pressure gauge reaches the specified value, turn the Damper control lever to Pressure. Guideline 0 bar Oil is pumped into the damper. The pressure gauge rises to the specified value. 3 bar 200268-10 – When the pressure gauge reaches the specified value, turn the Damper control lever to Vacuum.
SHOCK ABSORBER, SWINGARM – Clamp special tool in the vise. Nitrogen filling tool (T170S1) ( p. 226) – Connect the special tool to the pressure regulator of the filling cylinder. Filling gas - nitrogen – Adjust pressure regulator. Guideline Gas pressure 10 bar (145 psi) 201281-10 –...
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SHOCK ABSORBER, SWINGARM Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seri- ously alter the vehicle's ride behavior. – Extreme modifications to the adjustment of the suspension compo- nents can cause a serious deterioration in the handling characteris- tics and overload some components.
EXHAUST 10.1 Removing the manifold Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. Preparatory work – Remove the seat. ( p. 62) –...
EXHAUST – Position the exhaust clamp. – Tighten screw Guideline Screw, main silencer 12 Nm Copper paste clamp (8.9 lbf ft) 202034-11 – Plug in connector of the lambda sensor. Position the cable and secure it with cable binder 202035-10 –...
EXHAUST – Remove screws – Lift the rear fairing. 202036-10 – Remove screws – Remove the main silencer. 202037-10 10.4 Installing the main silencer – Position the main silencer. – Mount and tighten screws Guideline Screw, main silencer holder 25 Nm (18.4 lbf ft) 202037-11 –...
AIR FILTER 11.1 Removing the air filter Preparatory work – Remove the seat. ( p. 62) Main work – Remove screws . Take off air filter box top 601783-10 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine.
AIR FILTER Main work – Remove screws – Take off the voltage regulator and hang it to the side in a de-energized state. – Detach and expose hose 202038-10 – Remove screws 202039-10 – Remove screws 202040-10 – Loosen hose clip 202041-10 –...
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AIR FILTER – Position the air filter box. – Mount and tighten hose clip 202041-11 – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 202040-10 – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 202039-11 –...
FUEL TANK, SEAT, TRIM 12.1 Opening the filler cap Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...
FUEL TANK, SEAT, TRIM 12.4 Mounting the seat 601782-10 – 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.
FUEL TANK, SEAT, TRIM 12.7 Checking the fuel pressure Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...
FUEL TANK, SEAT, TRIM – Check the fuel pressure with the filler cap open. Fuel pressure When the fuel pump is active 3.3… 3.7 bar (48… 54 psi) » If the specification is not reached: – Check that the fuel line is clear. –...
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FUEL TANK, SEAT, TRIM – Remove screw on both sides. – Swing the rear end upwards and secure it. 202043-10 – Remove screws and the splash protector. 202046-10 – Remove screws – Pull out the fuel pump. 202047-10 – Disconnect both fuel hose connections –...
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FUEL TANK, SEAT, TRIM – Change fuel screen – Mount the fuel pump housing. 202051-10 – Connect both fuel hose connections – Attach connector 202048-10 – Position the fuel pump. – Mount and tighten screws Guideline Screw, fuel pump 4 Nm (3 lbf ft) 202047-10 –...
FUEL TANK, SEAT, TRIM – Mount and tighten screws Guideline Screw, side cover 5 Nm (3.7 lbf ft) 202036-12 Finishing work – Disconnect the battery. ( p. 83) – Mount the seat. ( p. 63) – Set the clock. ( p.
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FUEL TANK, SEAT, TRIM – Remove screw on both sides. – Swing the rear end upward and secure it. 202043-10 – Remove screws and the splash protector. 202046-10 – Remove screws – Pull out the fuel pump. 202047-10 – Disconnect both fuel hose connections –...
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FUEL TANK, SEAT, TRIM – Position the rear end. – Mount and tighten screw on both sides. Guideline Screw, fuel tank, bottom 25 Nm Loctite ® 243™ (18.4 lbf ft) 202043-10 – Lift the rear fairing. – Mount and tighten screws Guideline Screw, main silencer holder on fuel 25 Nm...
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 characteristic due to non-approved and/or non-recommended tires/wheels. – Only tires/wheels approved by KTM and with the corresponding speed index should be used. Warning Danger of accidents Reduced road grip with new tires. –...
DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufac- ture. KTM recommends that the tires are changed regardless of the actual wear, at the latest after 5 years. »...
WHEELS 13.5 Checking the rim run-out Warning Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. 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.
WHEELS – 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 dam- aged.
WHEELS Main work – Remove screws . Take off the brake disc. 202087-10 13.6.4 Installing the brake disc of the front brake Main work – Clean the contact surface of the brake disc. – Position the brake disc with the label facing outward. Mount and tighten screws Guideline Screw, front brake disc 14 Nm...
WHEELS Warning Danger of accidents No braking effect when operating the rear brake. – After installing the rear wheel, always operate the foot brake until the pressure point is reached. Main work – Check the rear hub rubber dampers. ( p. 80) –...
WHEELS 13.7.4 Installing the brake disc of the rear brake Main work – Clean the contact surface of the brake disc. – Position the brake disc with the label facing outward. Mount and tighten screws Guideline Screw, rear brake disc 14 Nm Loctite ®...
WHEELS Main work – 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 chain adjusters are in the same position relative to the reference marks...
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WHEELS – Pull on the upper section of the chain with the specified weight Guideline Weight of chain wear measurement 15 kg (33 lb.) 0 0 A – Measure 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.
WHEELS – Check the chain guide for wear. Info Wear is visible on the front of the chain guide. » If the light part of the chain guide is worn: – Change the chain guide. 400985-01 – Check that the chain guide is firmly seated. »...
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WHEELS Main work – Check bearing » If the bearing is damaged or worn: – Replace the bearings. – Check rubber dampers of the rear hub for damage and wear. » If the rubber dampers of the rear hub are damaged or worn: –...
WIRING HARNESS, BATTERY 14.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...
– Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.
WIRING HARNESS, BATTERY Main work – 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 alternator. With this device, you cannot overcharge the bat- tery.
WIRING HARNESS, BATTERY 14.7 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers in the vehicle. It is in the housing of the starter relay next to the battery. Preparatory work –...
WIRING HARNESS, BATTERY – Remove the defective fuse. Guideline Fuse 1 - 10 A - ignition, combination instrument Fuse 2 - 10 A - clock, ignition (EFI control unit) Fuse 3 - 10 A - EPT control unit Fuse 4 - 10 A - fuel pump Fuse 5 - 10 A - radiator fan Fuse 6 - 10 A - horn, brake light, turn signal Fuse 7 - 15 A - high beam, low beam, parking light, tail light, license plate lamp...
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WIRING HARNESS, BATTERY – Turn the adjusting wheel until the desired digit is next to marking 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. –...
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
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BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Press the brake caliper by hand onto the brake disc in order to retract the brake pistons.
BRAKE SYSTEM 15.3 Checking the free travel of the hand brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating.
BRAKE SYSTEM 15.6 Adding front brake fluid Warning Danger of accidents Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. Warning Skin irritation Brake fluid can cause skin irritation on contact.
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BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Cover the painted parts. – Remove screws – Remove cover with membrane. – Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid.
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
BRAKE SYSTEM – Stand the vehicle upright. – Remove screw cap with membrane – Press the brake caliper by hand onto the brake disc in order to retract the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does.
BRAKE SYSTEM 15.11 Adjusting the basic position of the foot brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating.
BRAKE SYSTEM 15.13 Adding rear brake fluid Warning Danger of accidents Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. Warning Skin irritation Brake fluid can cause skin irritation on contact.
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BRAKE SYSTEM – Cover the painted parts. – Take off screw cap with the washer and membrane. – Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid. Bleed syringe (50329050000) ( p.
LIGHTING SYSTEM, INSTRUMENTS 16.1 Combination instrument 16.1.1 Setting kilometers or miles Info If you change the unit, the value is retained and converted accordingly. Making the setting according to the country. Condition The motorcycle is stationary. – Switch on the ignition by turning the ignition key to position ON –...
LIGHTING SYSTEM, INSTRUMENTS – Switch on the ignition by turning the ignition key to position ON – Press the MODE button repeatedly until the TRIP 2 mode is active. – Keep the SET button pressed. The TRIP 2 display is set to 0.0. 400841-01 16.1.5 Setting the wheel circumference...
LIGHTING SYSTEM, INSTRUMENTS 16.2 Checking the headlight setting – Stand the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight. – Make another mark at a distance under the first mark.
LIGHTING SYSTEM, INSTRUMENTS 16.5 Installing the headlight mask with the headlight Main work – Connect the connectors of headlight and turn signal lights – Check lighting function. 601794-11 – Remove the cloth from the fender and position the headlight mask. Holding lugs reach into the headlight mask.
LIGHTING SYSTEM, INSTRUMENTS – 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 (W5W / socket W2.1x9.5d) ( p. 181) –...
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LIGHTING SYSTEM, INSTRUMENTS Main work (690 Enduro R EU/AUS/UK) – Remove the screw on the rear of the turn signal housing. – Tilt headlamp diffuser forward carefully and take it off. – Lightly squeeze the orange plug in the area of the holding lugs and take it off.
ENGINE 17.1 Removing the engine Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. ( p. 62) – Disconnect the battery. ( p. 82) – Raise the motorcycle with the work stand. ( p.
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ENGINE – Take off the engine sprocket. – Remove screws – Remove cable binders – Take off the clutch slave cylinder with the gasket and hang it to the side. Info Do not kink the clutch line. Do not activate the clutch lever if the clutch slave cylinder has been removed.
ENGINE – Detach connector of the oil pressure sensor. Remove screw – Release connection . Remove the line with the oil pressure sensor. 202078-10 – Remove screws . Remove the engine bearer. 202077-10 – Position the floor jack under the engine and fix it using the special tool. Floor jack attachment (75029055000) ( p.
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ENGINE Main work – Position the engine in the frame. 202081-10 – Mount swingarm pivot – Mount the screw of the swingarm pivot but do not tighten yet. – Mount screw connection of the lower engine attachment but do not tighten yet. 202080-11 –...
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ENGINE – Position the hoses of the engine breather, the SLS and the oil return line. Mount the spring band clamp using the special tool. Pliers for spring band clamp (60029057100) ( p. 217) 202076-11 – Attach the spark plug connector. –...
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ENGINE – Mount the engine sprocket with the chain. – Position the new lock washer and mount nut but do not tighten yet. – Position the rear wheel. – Mount the chain adjuster and nut. – Push the rear wheel forward so that the chain adjusters are on the tensioning screws, and tighten the nut Guideline Nut, rear wheel spindle...
Remove the motorcycle from the work stand. ( p. 11) – Take a short test ride. – Read out the fault memory using the KTM diagnostics tool. – Check the engine for leakage. – Check the engine oil level. ( p.
ENGINE 17.3.3 Removing starter motor – Remove screws . Take off the starter motor. 300001-01 17.3.4 Removing valve cover – Remove screws . Take off the valve cover with the valve cover seal. 300003-10 17.3.5 Removing the alternator cover – Remove screws .
ENGINE – Remove O-ring – Remove contact pin and the contact springs 300007-10 17.3.8 Removing oil filter – Remove screws. Remove the oil filter cover with the O-ring. – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) ( p.
ENGINE – Remove screw Info Look through the hole to check that the position hole of the balancer shaft is visible. – Screw in special tool Engine blocking screw (77329010000) ( p. 222) 300024-10 17.3.11 Removing water pump wheel – Remove screws .
ENGINE 17.3.13 Removing spacer and spring – Remove the spacer and spring of the shift shaft. 300154-10 17.3.14 Removing spark plug – Remove the spark plug using the special tool Spark plug wrench (75029172000) ( p. 222) 300016-10 17.3.15 Removing timing chain tensioner –...
ENGINE 17.3.17 Removing cylinder head – Remove screws – Alternately loosen screws and remove them. – Take off the cylinder head. 300029-10 17.3.18 Removing piston – Take off the cylinder head gasket – Remove screw – Push the cylinder upward. Info Push the cylinder upward only far enough to allow removal of the piston pin.
ENGINE – Install the special tool on the rotor. Hold it tight using the special tool and pull off the rotor by turning the screw in. Extractor (58429009000) ( p. 215) – Remove the special tool. 302120-10 17.3.20 Removing timing chain rails –...
ENGINE 17.3.22 Removing crankshaft position sensor – Remove the screws of crankshaft position sensor – Pull cable support sleeve out of the engine case. Take off the crankshaft posi- tion sensor. 300151-10 17.3.23 Removing clutch cage – Clamp the antihopping clutch with special tool Assembly screws (75029033000) ( p.
ENGINE – Take off the stepped washer and remove the half-washers – Take off the clutch cage. 302125-10 – Remove needle bearing and supporting plate 300056-10 17.3.24 Removing primary gear – Plug the special tool into the crankshaft. Protection cover (75029090000) ( p.
ENGINE 17.3.26 Removing shift shaft – Push sliding plate away from the shift drum locating . Remove shift shaft with the washer. 300066-10 17.3.27 Removing shift drum locating – Remove screw – Press locking lever away from shift drum locating and take off the shift drum locating.
ENGINE – Remove both oil pump shafts with internal rotors – Take the external rotors out of the engine case. 300072-10 17.3.30 Removing left engine case – Remove screws – Swing the left section of the engine case up and remove the nut or screw of the engine fixing arm.
ENGINE 17.3.32 Removing transmission shafts – Remove the shift rail 300079-10 – Swing shift forks to one side. – Remove shift drum 300080-10 – Remove shift forks Info Ensure that the pins remain in place. 300081-10 – Remove the lock ring and the stop disk.
ENGINE 17.4 Work on individual parts 17.4.1 Work on the right section of the engine case – Remove oil jet – Remove bearing locks of the main shaft bearing , of the countershaft bearing and of the shift drum bearing –...
ENGINE – Mount and tighten the oil jet Guideline Oil nozzle for conrod bear- 2 Nm Loctite ® 243™ ing lubrication (1.5 lbf ft) – Blow compressed air through all oil channels and check that they are clear. – Position the cover plate .
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ENGINE Info When pressing the bearing in, ensure that the engine case section is level to prevent damage. Only press the bearings in via the outer bearing race; otherwise, the bear- ings will be damaged when they are pressed in. –...
ENGINE 17.4.3 Work on the clutch cover – Remove the shaft seal ring of the crankshaft. – Press in a new shaft seal ring with the open side facing inward until it stops. Info Support the clutch cover sufficiently when pressing in. –...
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ENGINE Main work – Position the crankshaft with the special tool in the press. Under part, pressing-out tool (75029047051) ( p. 220) – Position the special tool between the crankwebs. Upper part, pressing-out tool (75029047050) ( p. 220) – Press the crank pin with the push-out drift of the special tool out of the upper crankweb.
ENGINE – Position the special tool with the heel at the bottom. Pressing device for crankshaft, complete (75029047000) ( p. 219) – Press the upper crankweb in as far as possible. Info The press mandrel must be applied above the crank pin. –...
ENGINE – Place the drive wheel on the crankshaft. The dowel of the crankshaft must fit in the drill hole The side of the drive wheel with the punch mark must be visible after assembly, and the side with the bevel must be in contact with the crankweb.
ENGINE » If the measured value does not equal the specified value: – Remove the crankshaft. – Remove the crankshaft bearing inner ring. ( p. 125) – Calculate the thickness of the compensation shims. – Add or remove compensation shims equally on both sides. Info If the axial clearance is too small, remove compensation shims.
ENGINE – The cylinder size is marked on the side of the cylinder. 300103-10 – Check the sealing area of the cylinder head for distortion using a straight edge and the special tool. Feeler gauge (59029041100) ( p. 216) ≤ 0.10 mm (≤ 0.0039 in) Cylinder/cylinder head - sealing area distortion »...
ENGINE – Measure the piston at the piston skirt, at right angles to the piston pin, at a distance Guideline Distance 31.5 mm (1.24 in) Piston - diameter Size I 101.955… 101.965 mm (4.01397… 4.01436 in) Size II 101.965… 101.975 mm (4.01436… 4.01476 in) 302138-10 Info...
ENGINE » If the measured value does not meet specifications: – Change the oil pump and, if necessary, the engine case. 17.4.17 Replacing autodecompressor – Take the lock ring off the autodecompression shaft and dispose of it. 300107-10 – Pull the autodecompression shaft from the camshaft.
ENGINE – Place two compensating disks or similar aids next to the piston of the timing chain tensioner. This should ensure that when pushed down, the piston does not fully withdraw. Guideline Thickness of the compensating disks 2… 2.5 mm (0.08… 0.098 in) –...
ENGINE – Screw a suitable screw into the rocker arm shafts . Pull out the rocker arm shafts. – Take off the rocker arm 300114-10 17.4.21 Changing camshaft bearing Preparatory work – Remove the rocker arm. ( p. 133) Main work –...
ENGINE 17.4.22 Removing valves – Take shims out of the valve spring retainers and lay them to one side according to their normal built-in position. 300115-10 – Pretension the valve springs using the special tool. Valve spring compressor (59029019000) ( p.
ENGINE 17.4.24 Checking valve springs – Check the valve springs for fractures and wear (visual check). » If the valve spring is fractured or worn: – Change the valve spring. – Measure the valve spring lengths. Valve spring Minimum length (without valve 42.3 mm (1.665 in) spring cap) »...
ENGINE 17.4.27 Installing valves – Position the valve spring cap . Install new valve stem seals – Mount valves according to their normal built-in position. – Install the valve springs and the spring retainers. 0 0 5 0 0 4 0 0 1 0 0 2 0 0 3...
ENGINE – Install and tighten the screws of the rocker arm shafts. Guideline Screw, rocker arm shaft 12 Nm (8.9 lbf ft) 300113-11 17.4.29 Disassembling the antihopping clutch – Clamp the clutch in a vise. Info Use soft jaws. – Carefully loosen and gradually remove the special tool 300120-10 –...
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ENGINE 0 0 bk 0 0 4 0 0 5 0 0 6 0 0 2 0 0 9 0 0 b l 0 0 1 0 0 b o 0 0 3 0 0 b n 0 0 b m 0 0 7 0 0 8 300123-01...
ENGINE – Check clutch facing discs for discoloration and scoring. » If there is discoloration or scoring: – Change all clutch facing discs. – Check the thickness of clutch facing discs ≥ 2.5 mm (≥ 0.098 in) Clutch facing disc - thickness »...
ENGINE 17.4.32 Checking shift mechanism – Check the shift forks (see ) for damage and wear (visual check). 0 0 A » If there is damage or wear: – 0 0 1 Change the shift fork and gear wheel pair. 0 0 4 0 0 1 –...
ENGINE 17.4.34 Disassembling the main shaft 301980-01 – Fix the main shaft in the vise with the geared end facing downward. Guideline Use soft jaws. – Remove stop disk and second-gear fixed gear – Remove the sixth-gear idler gear – Remove the split needle bearing and stop disk –...
ENGINE – Remove stop disk and first-gear idler gear – Remove needle bearing and stop disk – Remove fifth-gear sliding gear and lock ring – Remove stop disk and third-gear idler gear – Remove needle bearing and the fourth-gear idler gear –...
ENGINE » If the sliding gear does not move easily: – Change the sliding gear or the main shaft. – Check sliding gears for smooth operation in the profile of countershaft » If the fixed gear does not move easily: –...
ENGINE 17.4.38 Assembling countershaft Info Use new lock rings in every repair job. Preparatory work – Oil all parts carefully before assembling. – Check the transmission. ( p. 143) Main work 300128-02 – Fix the countershaft in the vise with the geared end facing downward. Guideline Use soft jaws –...
ENGINE 17.4.39 Checking the starter drive 300129-01 – Check the teeth and seating of the starter idler gear for damage and wear. » If there is damage or wear: – Replace the starter idler gear and/or needle bushing. – Check the teeth and seating of the torque limiter for damage and wear.
ENGINE – Compress the expansion ring and remove it, using suitable pliers. – Take the freewheel out of the primary gear. 300128-10 17.4.41 Checking freewheel – Insert the freewheel gear in the primary gear , turning the primary gear clock- wise;...
ENGINE – Insert the lock ring into the groove with suitable pliers and check that it is seated correctly. 300127-11 17.5 Engine assembly 17.5.1 Installing transmission shafts – Clamp the right section of the engine case. Holder for engine assembly stand (75012001070) ( p.
ENGINE – Install the shift rail – Check the transmission for smooth operation. 300079-11 – Install the shim and lock ring of the countershaft. 300082-11 17.5.2 Installing crankshaft and balancer shaft – Mount the special tool on the alternator side of the crankshaft. Mounting sleeve (75029080000) ( p.
ENGINE 17.5.3 Installing left engine case – Mount the dowels. – Mount the O-ring – Degrease the sealing area. Apply the sealing compound to the left engine case half. Loctite ® 5910 302132-11 – Put on the left engine case half. If necessary, tap lightly with a rubber mallet and turn the transmission shafts.
ENGINE 17.5.5 Installing locking lever – Position locking lever with sleeve and spring – Mount and tighten screw Guideline Screw, locking lever 10 Nm Loctite ® 243™ (7.4 lbf ft) 300069-11 17.5.6 Installing shift drum locating – Press locking lever down and position shift drum locating.
ENGINE – Push on the starter idler gear with washer. Mount lock ring. – Push on the needle bearing and torque limiter with washer. Mount lock ring. 300064-11 17.5.9 Installing primary gear – Ensure that the spring washer is seated properly. –...
ENGINE – Position a new lock washer and install the nut – Lock the clutch basket and primary gear using special tool and tighten the nut. Guideline Nut, inner clutch hub M20x1.5 100 Nm Loctite ® 243™ (73.8 lbf ft) Gear segment (75029081000) ( p.
ENGINE 17.5.12 Installing timing chain and timing chain sprocket – Heat the timing chain sprocket and push it immediately on to the crankshaft. Guideline 100 °C (212 °F) – Mount lock ring 300150-10 – Thread the timing chain in and lay it over the timing chain sprocket. Info If the timing chain is not new, pay attention to the direction of travel.
ENGINE – Mount the tab washer and the nut . Tighten nut. Guideline Rotor nut M18x1.5 100 Nm (73.8 lbf ft) 300043-10 17.5.15 Adjusting crankshaft position sensor distance – Adjust the distance between the crankshaft position sensor and the conductive element of the rotor using the special tool Guideline Crankshaft position sensor/rotor -...
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ENGINE – Ensure that piston marking faces the outfeed side. 302599-10 – Apply a thin layer of sealing compound in area Loctite ® 5910 – Place the cylinder base gasket on. Info Make sure the grooved pins are seated correctly. 302598-10 –...
ENGINE – Remove the cloth. – Keep the timing chain tensioned. Push the cylinder down carefully and let the grooved pins engage. 300039-10 17.5.18 Installing cylinder head – Put on the cylinder head gasket. Info Make sure the grooved pins are seated correctly. –...
ENGINE – Position the camshaft support plate . Mount and tighten screw Guideline Screw, camshaft support 10 Nm Loctite ® 243™ plate (7.4 lbf ft) 300022-10 17.5.20 Installing timing chain tensioner – Insert the timing chain tensioner – Mount and tighten plug with the new seal ring.
ENGINE – Remove the special tool. Engine blocking screw (77329010000) ( p. 222) – Mount and tighten screw with the washer. Guideline Screw plug, crankshaft clamp 20 Nm (14.8 lbf ft) 306140-10 17.5.22 Adjusting valve clearance – Remove screws Info Make sure that the crankshaft is at top dead center.
ENGINE 17.5.23 Installing spark plug – Mount and tighten the spark plug using the special tool. Guideline Spark plug M12x1.25 18 Nm (13.3 lbf ft) Spark plug wrench (75029172000) ( p. 222) 300016-11 17.5.24 Installing spacer and spring – Install the spacer and spring of the shift shaft.
ENGINE – Put on the water pump cover . Mount and tighten screws. Guideline Screw, water pump cover 10 Nm (7.4 lbf ft) 300012-12 17.5.27 Installing thermostat – Position the thermostat with the gasket. The drill hole must face upward. –...
ENGINE – Install the gear position sensor – Position the ground wire – Mount and tighten the screws. Guideline Loctite ® 243™ Screw, gear sensor 5 Nm (3.7 lbf ft) 302126-11 17.5.30 Installing the spacer – Grease spacer in area and O-ring before mounting.
ENGINE – Position the oil screen with O-rings. – Mount and tighten screw plug with the O-ring. Guideline Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) 300161-11 17.5.32 Installing alternator cover – Apply sealing compound lightly in the area of the cable sleeve. –...
ENGINE 17.5.34 Installing valve cover – Put the valve cover in place with the seal. Mount and tighten screws Guideline Screw, valve cover 10 Nm (7.4 lbf ft) 300003-10 17.5.35 Removing the engine from the engine assembly stand – Remove the screw or the nut –...
CLUTCH 18.1 Checking/rectifying the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...
WATER PUMP, COOLING SYSTEM 19.1 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.
WATER PUMP, COOLING SYSTEM – Remove the cap from compensating tank and add coolant to the level shown in the figure. – Mount the cap of the compensating tank. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
WATER PUMP, COOLING SYSTEM » If the coolant level does not meet specifications: – Correct the coolant level and find out the cause of the loss. Alternative 1 Coolant ( p. 210) Alternative 2 Coolant (mixed ready to use) ( p.
LUBRICATION SYSTEM Main work – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level. The engine oil must be between the lower and upper edge of the oil level viewer. » If the engine oil level is not at the specified level: –...
LUBRICATION SYSTEM – Change the oil filter. Check oil pumps for wear. Check that all oil holes are clear. – Switch off the engine. Warning Danger of burns Some vehicle components get very hot when the machine is driven. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.
LUBRICATION SYSTEM – 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 20.6 Removing the oil filter Warning...
LUBRICATION SYSTEM 20.8 Cleaning the oil screens Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.
LUBRICATION SYSTEM 20.9 Filling up with engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. Main work – 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)
IGNITION SYSTEM 21.1 Alternator - checking the stator winding Condition The stator is disconnected. Preparatory work – Remove the seat. ( p. 62) – Take off the side cover. ( p. 63) Main work Stator winding, measurement I - check the resistance –...
IGNITION SYSTEM 21.3 Ignition coil - checking the secondary winding Condition Ignition coil cylinder 1 is disconnected. Spark plug connector cylinder 1 has been removed. Preparatory work – Remove the seat. ( p. 62) – Remove the fuel tank. Main work Ignition coil cylinder 1 - check the secondary winding resistance –...
TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 690 cm³ (42.11 cu in) Stroke 84.5 mm (3.327 in) Bore 102 mm (4.02 in) Compression ratio 12.5:1 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)
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TECHNICAL DATA Exhaust 2.00 mm (0.0787 in) Valve - run-out ≤ 0.05 mm (≤ 0.002 in) On the valve plate ≤ 0.05 mm (≤ 0.002 in) On the valve stem ≤ 0.10 mm (≤ 0.0039 in) Cylinder/cylinder head - sealing area distortion Cylinder - bore diameter Size I 102.000…...
Continental TKC 80 Continental TKC 80 (690 Enduro R USA) 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...
TECHNICAL DATA 22.8 Fork Fork part number 14.18.7L.10 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) 472 mm (18.58 in)
CLEANING/PROTECTIVE TREATMENT 23.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts.
CLEANING/PROTECTIVE TREATMENT 23.2 Checks and maintenance steps for winter operation Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggres- sive road salt. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.
– Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the lift stand. ( p. 10) – Cover the motorcycle with a tarp or similar cover that is permeable to air.
Final check: Check the vehicle for roadworthiness and take a test ride. ○ ● ● Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● ● Make the service entry in KTM DEALER.NET and in the service record.
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WIRING DIAGRAM Components: EFI control unit Fuse Battery Alternator Starter relay with main fuse Start auxiliary relay Starter motor Voltage regulator Connector for accessory ground (terminal 31) ACC 1 (not assigned) X291 X292 Connector for accessory plus (terminal 30) ACC 1 (not assigned)
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WIRING DIAGRAM Components: EFI control unit EPT control unit Fuse Light relay Power relay Combination instrument Ignition/steering lock Emergency OFF switch, electric starter button X295 Diagnostics connector...
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WIRING DIAGRAM Components: Turn signal relay Combination instrument Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right High beam/low beam switch, horn button, turn signal switch...
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WIRING DIAGRAM Components: EFI control unit Throttle position sensor circuit A Intake air temperature sensor Rollover sensor Side stand switch Accelerator position sensor Gear position sensor Oil pressure sensor Combination instrument...
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WIRING DIAGRAM Components: EFI control unit Ambient air pressure sensor Engine coolant temperature sensor (cylinder 1) Fuel tank sensor Crankshaft position sensor Clutch switch Manifold absolute pressure sensor (cylinder 1) Combination instrument Map‑Select Switch Cable colors: Black Brown Blue Green Gray Light blue Orange...
Brake fluid DOT 4 / DOT 5.1 According to – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Castrol and Motorex ® products. Supplier Castrol –...
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Hydraulic fluid (15) According to – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Motorex ® products. Supplier Motorex ® –...
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 specifi- cation.