KTM 690 Enduro R USA 2013 Owner's Manual
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KTM 690 Enduro R USA 2013 Owner's Manual

KTM 690 Enduro R USA 2013 Owner's Manual

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2013
OWNER'S MANUAL
690 Enduro R USA
Art. no. 3211952en

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Summary of Contents for KTM 690 Enduro R USA 2013

  • Page 1 2013 OWNER'S MANUAL 690 Enduro R USA Art. no. 3211952en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.
  • Page 4 DEAR KTM CUSTOMER 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. Issued by: TÜV Management Service KTM-Sportmotorcycle AG 5230 Mattighofen, Austria...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SERIAL NUMBERS ............26 TABLE OF CONTENTS MEANS OF REPRESENTATION ........7 Chassis number ..........26 Symbols used ............7 Type label ............26 Formats used............7 Key number............27 SAFETY ADVICE.............. 8 Engine number ..........27 Use definition - intended use ........
  • Page 6 TABLE OF CONTENTS 6.10.12 Setting/resetting display TRIP 2 ...... 40 10.2 Adjusting the compression damping of the fork..66 6.10.13 TRIP F display..........41 10.3 Adjusting the rebound damping of the fork ... 67 6.10.14 Coolant temperature indicator ......41 10.4 Compression damping of the shock absorber..
  • Page 7 TABLE OF CONTENTS 11.12 Installing the air filter ........86 12.13 Changing the rear brake linings ....113 11.13 Checking the chain for dirt........87 13 WHEELS, TIRES ............117 11.14 Cleaning the chain ..........87 13.1 Removing the front wheel ......
  • Page 8 TABLE OF CONTENTS 22 TECHNICAL DATA............179 15.4 Draining the coolant ........149 22.1 Engine ............179 15.5 Filling/bleeding the cooling system ....150 22.2 Engine tightening torques ......... 180 16 TUNING THE ENGINE..........152 22.3 Capacities ............183 16.1 Checking the play in the throttle cable ....

  • 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 performed by an authorized KTM workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required.

  • Page 10: Safety Advice

    SAFETY ADVICE Use definition - intended use KTM sport motorcycles are designed and constructed to meet the normal demands of regular road and light offroad operation (dirt roads), but not for use on race courses. Info The motorcycle is only authorized for operation on public roads in the homologated version.

  • Page 11: Degrees Of Risk And Symbols

    SAFETY ADVICE Degrees of risk and symbols Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

  • Page 12: Overview Of Labels

    SAFETY ADVICE Overview of labels B01292-10...
  • Page 13 SAFETY ADVICE Type label, Canada Type label, USA Information, emission control Information, noise emission Information, suspension setting Information, chain tension Information, putting into operation 101615-10 Type label, Canada...
  • Page 14 SAFETY ADVICE 101616-01 Type label, USA B01294-01 Information, emission control...
  • Page 15 SAFETY ADVICE B01295-01 Information, noise emission Information, suspension setting 101619-01...

  • Page 16: Reporting Safety Defects

    If you believe that your vehicle has a defect which could cause an accident resulting in injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc. If NHTSA receives multiple similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.

  • Page 17: Noise Emission Warranty

    Noise emission warranty KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA 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 18: Tampering Warning

    SAFETY ADVICE Tampering warning Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof: 1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate pur- chaser or while it is in use, or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 19: Protective Clothing

    Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. 2.12 Work rules Special tools are necessary for certain tasks.

  • Page 20: Environment

    Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.

  • Page 21: Important Notes

    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 record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 22: Figures

    Please follow the instructions in the text. Customer service Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM. A list of authorized KTM dealers can be found on the KTM website.

  • Page 24: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left side (example) B01296-10...
  • Page 25 VIEW OF VEHICLE Hand brake lever ( p. 29) Clutch lever ( p. 29) Handrails ( p. 44) Filler cap Engine number ( p. 27) Shift lever ( p. 45) Side stand ( p. 46) Seat release ( p. 43) Compression damping of the shock absorber ( p.

  • Page 26: View Of Vehicle, Rear Right Side (Example)

    VIEW OF VEHICLE View of vehicle, rear right side (example) B01297-10...
  • Page 27 VIEW OF VEHICLE Light switch ( p. 31) Turn signal switch ( p. 31) Horn button ( p. 30) Ignition/steering lock ( p. 33) Function buttons ( p. 34) Indicator lamps ( p. 35) Emergency OFF switch ( p. 32) Electric starter button ( p.

  • Page 28: Serial Numbers

    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. B01289-10...

  • Page 29: Key Number

    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. 100211-10...

  • Page 30: Fork Part Number

    SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub. 601780-10 Shock absorber part number The shock absorber part number is on the left of the shock absorber. 101048-10...

  • Page 31: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 601766-10 Hand brake lever The hand break lever is fitted on the right side of the handlebar. The hand brake lever operates the front brake. 601767-10...

  • Page 32: Throttle Grip

    CONTROLS Throttle grip The throttle grip is fitted on the right side of the handlebar. 601767-11 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. •...

  • Page 33: 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 downward. In this position, the low beam and tail light are switched on. High beam on – Light switch is turned upward. In this position, the high beam and tail light are switched on.

  • Page 34: Emergency Off Switch

    CONTROLS Emergency OFF switch The emergency OFF switch is fitted on the right side of the handlebar. Possible states Emergency OFF switch off – In this position, the ignition circuit is inter- rupted, a running engine stops, and the engine cannot be started. Emergency OFF switch on –...

  • Page 35: Ignition/Steering Lock

    CONTROLS Ignition/steering lock The ignition/steering lock is located in front of the seat. Possible states Ignition OFF – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. The ignition key can be removed.

  • Page 36: Function Buttons

    CONTROLS 6.10.2 Function buttons You can change the display mode with the MODE button Possible display modes are distance traveled (ODO), trip master 1 (TRIP 1) and trip mas- ter 2 (TRIP 2). Press the SET button to reset the trip master 1 function (TRIP 1) and trip master 2 func- tion (TRIP 2) to 0.0.

  • Page 37: Indicator Lamps

    CONTROLS 6.10.4 Indicator lamps The indicator lamps offer additional information about the operating state of the motorcy- cle. Possible states The turn signal indicator light flashes green simultaneously with the turn signals – Turn signal light is switched on. The idling speed indicator lamp lights up green – The transmission is switched to idle.

  • Page 38: Display

    CONTROLS 6.10.5 Display When the ignition is switched on, all display segments light up for one second as a function check. 400836-01 LEnGth After the display function check, the wheel circumference LEnGth is displayed for one sec- ond. Info 2205 mm equals the circumference of the 21" front wheel with a series production tire.

  • Page 39: Speed Display

    CONTROLS 6.10.6 Speed display The speed is shown in kilometers per hour km/h or in miles per hour mph. 400838-10 6.10.7 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.

  • Page 40: Time

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

  • Page 41: 6.10.10 Odo Display

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

  • Page 42: Setting/Resetting Display Trip 2

    CONTROLS – Switch on the ignition by turning the ignition key to position ON – Press the MODE button repeatedly until the TRIP 1 mode is active. – Keep the SET button pressed. The TRIP 1 display is set to 0.0. 400840-01 6.10.12 Setting/resetting display TRIP 2 Info...

  • Page 43: 6.10.13 Trip F Display

    CONTROLS 6.10.13 TRIP F display 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 The low fuel warning lamp lights up in parallel to the TRIP F display. 400842-01 6.10.14 Coolant temperature indicator The temperature display consists of 12 bars.

  • Page 44: Opening The Filler Cap

    CONTROLS 6.11 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. –...

  • Page 45: Closing Filler Cap

    CONTROLS 6.12 Closing filler cap – Put the filler cap back on and turn the ignition key 90° clockwise. – Remove the ignition key and fold down the cover. 601771-01 6.13 Seat release The seat can be released using strap 601772-10...

  • Page 46: Handrails

    CONTROLS 6.14 Handrails The handrails are used for moving the motorcycle around. When you have a passenger, the passenger can hold on the handrails during the journey. 601773-10 6.15 Passenger footrests The passenger footrests can be folded up and down. Possible states Passenger footrests folded up –...

  • Page 47: Shift Lever

    CONTROLS 6.16 Shift lever The shift lever is mounted on the left side of the engine. 100215-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 100212-10...

  • Page 48: Foot Brake Lever

    CONTROLS 6.17 Foot brake lever Foot brake lever is located in front of the right footrest. The rear brake is engaged with the foot brake lever. 100232-10 6.18 Side stand The side stand is located on the left side of the vehicle. The side stand is used for parking the motorcycle.

  • Page 49: Preparing For Use

    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. –...

  • Page 50: 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 51: Loading The Vehicle

    PREPARING FOR USE Guideline Maximum engine speed During the first: 1,000 km (621.4 mi) 6,000 rpm After the first: 1,000 km (621.4 mi) 7,800 rpm – Avoid fully opening the throttle! Loading the vehicle Warning Danger of accidents Unstable handling characteristics. –...
  • Page 52 PREPARING FOR USE Warning Danger of accidents Poor visibility for other road users due to slipped baggage. – If the tail light is covered, you are less visible to traffic behind you, especially in the dark. Check that your baggage is fixed properly at regular intervals.

  • Page 53: Riding Instructions

    RIDING INSTRUCTIONS Performing checks and vehicle care when preparing for use Info Before each use, check the state and roadworthiness of the vehicle. Make sure that the vehicle is in perfect technical condition before use. – Check the engine oil level. ( p.

  • Page 54: Starting

    RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 55: Starting Off

    RIDING INSTRUCTIONS Info Do not press the electric starter button until the combination instrument func- tion check is finished. When starting, DO NOT open the throttle. If you open the throttle during the start- ing procedure, fuel is not injected by the engine management system and the engine cannot start.
  • Page 56 RIDING INSTRUCTIONS Warning Danger of accidents Malfunctions caused by incorrect ignition key position. – Do not change the ignition key position during a journey. Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle. – Make all adjustments when the vehicle is at a standstill. Warning Risk of injury Falling off of the passenger.
  • Page 57 If you continue with the coolant temperature warning lamp alight, you may have engine failure. Info If unusual noises arise during operation, stop immediately, park the vehicle properly, and contact an authorized KTM workshop.
  • Page 58 RIDING INSTRUCTIONS – When conditions allow (incline, road situation, etc.), you can shift into a higher gear. – Release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle. Info You can see the positions of the 6 forward gears in the figure.

  • Page 59: Braking

    Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. – Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Failure of brake system.

  • Page 60: Stopping, Parking

    RIDING INSTRUCTIONS Warning Danger of accidents Delayed brake action on salted roads. – There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the deposits from the discs by carefully applying the brakes. –...

  • Page 61: Transport

    RIDING INSTRUCTIONS – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first. Note Material damage Damage and destruction of components by excessive load. –...

  • Page 62: Refueling

    RIDING INSTRUCTIONS Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run.
  • Page 63 – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards.
  • Page 64 RIDING INSTRUCTIONS – Press the SET button for two seconds. switches off. TRIP F is set to 0.0 and the display The fuel level warning lamp returns to the previous display mode. Info If you do not press the SET button , the reset takes place automatically after approx.

  • Page 65: Service Schedule

    Check that the electrical equipment is functioning correctly. • • • • • • Read out the fault memory using the KTM diagnostics tool. • • Check the measured service values with the KTM diagnostics tool. • • • Change the engine oil and filter, clean the oil screens.
  • Page 66 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.
  • Page 67 SERVICE SCHEDULE K10N: Once after 1,000 km (621.4 mi) K100A: Every 10,000 km (6,214 mi) or annually or after every sporting use K200A: Every 20,000 km (12,428 mi) or every 2 years...

  • Page 68: Tuning The Chassis

    TUNING THE CHASSIS 10.1 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 69: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS 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 damping. 10.3 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork rebound behavior. –...

  • Page 70: Compression Damping Of The Shock Absorber

    Adjusting the low-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. (Your authorized KTM workshop will be glad to help.)

  • Page 71: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    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. (Your authorized KTM workshop will be glad to help.)

  • Page 72: Adjusting The Rebound Damping Of The Shock Absorber

    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. (Your authorized KTM workshop will be glad to help.)

  • Page 73: Measuring The Unloaded Rear Wheel Sag

    TUNING THE CHASSIS – Turn adjusting screw clockwise up 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 Full payload 10 clicks...

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

    TUNING THE CHASSIS Finishing work – Remove the motorcycle from the lift stand. ( p. 78) 10.9 Checking the static sag of the shock absorber – Measure distance of rear wheel unloaded. ( p. 71) – Hold the motorcycle upright with the aid of an assistant. –...

  • Page 75: Checking The Riding Sag Of The Shock Absorber

    Adjusting the spring preload 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. (Your authorized KTM workshop will be glad to help.)
  • Page 76 TUNING THE CHASSIS Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. Preparatory work – Raise the motorcycle with the work stand. – Remove the seat. ( p. 84) –...

  • Page 77: Adjusting The Riding Sag

    TUNING THE CHASSIS – Remove the motorcycle from the work stand. 10.12 Adjusting the riding sag Preparatory work – Raise the motorcycle with the work stand. – Remove the seat. ( p. 84) – Take off the side cover. – Remove the shock absorber.

  • Page 78: Handlebar Position

    TUNING THE CHASSIS 10.13 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)
  • Page 79 TUNING THE CHASSIS – 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 (14.8 lbf ft)

  • Page 80: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 11.1 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.

  • Page 81: Bleeding The Fork Legs

    SERVICE WORK ON THE CHASSIS – Remove the motorcycle from the lift stand and rest it on its side stand. – Remove the lift stand. B01290-01 11.3 Bleeding the fork legs Preparatory work – Lean the motorcycle on the side stand. Main work –...

  • Page 82: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS 11.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 78) – Loosen the fork protection. ( p. 81) Main work – Push dust boot of both fork legs downwards.

  • Page 83: Loosening The Fork Protection

    SERVICE WORK ON THE CHASSIS 11.5 Loosening the fork protection – Remove screws and take off clamp. – Remove screws on left fork leg. Push the fork protection downwards. – Remove screws on the right fork leg. Push the fork protector downward. B01282-10 11.6 Positioning the fork protector...

  • Page 84: Checking The Steering Head Bearing Play

    Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become damaged over time.

  • Page 85: Adjusting The Play Of The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS 11.8 Adjusting the play of the steering head bearing Preparatory work – Raise the motorcycle with the lift stand. ( p. 78) Main work – Loosen screw . Remove screw – Loosen and retighten screw Guideline Screw, top steering head M20x1.5...

  • Page 86: Removing The Seat

    SERVICE WORK ON THE CHASSIS 11.9 Removing the seat – Pull on strap and raise the rear of the seat at the same time. – Pull back the seat and lift it off. 601772-10 11.10 Mounting the seat 601782-10 – Hook slot of the seat onto screw , press the rear downward and at the same time push it forward.

  • Page 87: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 11.11 Removing the air filter Preparatory work – Remove the seat. ( p. 84) 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.

  • Page 88: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 11.12 Installing the air filter Main work – Clean the air filter box. – Mount air filter Info The air filter must lie flush against the air filter box along the entire sealing sur- face If the air filter is not correctly mounted, dust and dirt can enter the engine and cause damage.

  • Page 89: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS 11.13 Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 87) 400678-01 11.14 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. –...

  • Page 90: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 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 91: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS – 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 92 SERVICE WORK ON THE CHASSIS Preparatory work – Check the chain tension. ( p. 88) 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...

  • Page 93: Check The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

    SERVICE WORK ON THE CHASSIS 11.17 Check the chain, rear sprocket, engine sprocket and chain guide Preparatory work – Raise the motorcycle with the lift stand. ( p. 78) Main work – Shift gear to neutral. – Check the rear sprocket and engine sprocket for wear. »...
  • Page 94 SERVICE WORK ON THE CHASSIS – 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 differ- ent chain positions.
  • Page 95 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with or below the chain sliding guard: – Replace the chain sliding guard. – Check that the chain sliding guard is firmly seated. »...
  • Page 96 SERVICE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated. »...
  • Page 97 SERVICE WORK ON THE CHASSIS – Check that the chain guide is firmly seated. » If the chain guide is loose: – Tighten the chain guide. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 101068-01 Finishing work – Remove the motorcycle from the lift stand. ( p.

  • Page 98: Adjusting Chain Guide

    SERVICE WORK ON THE CHASSIS 11.18 Adjusting chain guide – Remove screws . Take off the chain guide. Condition Number of teeth: ≤ 44 teeth – Insert nut in hole . Position the chain guide. – Mount and tighten screws Guideline Screw, chain guide 8 Nm (5.9 lbf ft)

  • Page 99: Adjusting Basic Position Of Clutch Lever

    SERVICE WORK ON THE CHASSIS 11.19 Adjusting basic position of clutch lever Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar. The range of adjustment is limited.

  • Page 100: Removing The Engine Guard

    SERVICE WORK ON THE CHASSIS – 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 101: Installing The Engine Guard

    SERVICE WORK ON THE CHASSIS 11.22 Installing the engine guard – Slide the engine guard into holders at the rear. – Position the engine guard. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 202021-11...

  • Page 102: Brake System

    BRAKE SYSTEM 12.1 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.

  • Page 103: Checking The Brake Discs

    Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs in several places to ensure that it...

  • Page 104: Checking The Front Brake Fluid Level

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 105: Adding Front Brake Fluid

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 106: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. –...

  • Page 107: Changing The Front Brake Linings

    If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)
  • Page 108 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 109 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. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does.
  • Page 110 BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 400418-10 – Insert the brake linings, insert the pin, and mount the cotter pin. – Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

  • Page 111: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 12.8 Checking the free travel of 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 over- heating.

  • Page 112: Checking Rear Brake Fluid Level

    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. (Your authorized KTM workshop will be glad to help.)

  • Page 113: Adding Rear Brake Fluid

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.
  • Page 114 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 115: Checking The Rear Brake Linings

    – Change the rear brake linings. p. 113) 100260-10 12.13 Changing the rear brake linings Warning Danger of accident Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.)
  • Page 116 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
  • Page 117 BRAKE SYSTEM Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.
  • Page 118 BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 400419-11 – Insert the brake linings, insert the pin, and mount the cotter pin. – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

  • Page 119: Wheels, Tires

    WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 78) Main work – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons.

  • Page 120: Installing The Front Wheel

    WHEELS, TIRES – 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. 601809-10 –...
  • Page 121 WHEELS, TIRES – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Replace the wheel bearing. – Clean and grease the shaft seal rings and bearing surface of the distance bush- ings.

  • Page 122: Removing Rear Wheel

    WHEELS, TIRES 13.3 Removing rear wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 78) Main work – Press the brake caliper by hand on to the brake disc in order to press back the brake piston.

  • Page 123: Installing The Rear Wheel

    WHEELS, TIRES 13.4 Installing the rear wheel 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. Warning Danger of accidents No braking effect when operating the rear brake.

  • Page 124: Checking The Rear Hub Rubber Dampers

    WHEELS, TIRES – Push the rear wheel forward as far as possible and lay the chain on the rear sprocket. – Install the wheel spindle, the chain adjusters and the nut. 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 Info Mount the left and right chain adjusters...
  • Page 125 WHEELS, TIRES 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: –...

  • Page 126: Checking The Tire Condition

    Danger of accidents Uncontrollable vehicle handling in the event of a flat tire. – In the interest of safety, replace damaged or worn tires immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.

  • Page 127: 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 128: Checking The Spoke Tension

    Correct the tire pressure. – Mount the protection cover. 13.8 Checking the spoke tension Warning Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.)
  • Page 129 WHEELS, TIRES Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes. If the spokes are too tight, they can break due to local overload. Check the spoke tension regularly, especially on a new motorcycle. – Briefly strike each spoke with a screwdriver blade.

  • Page 130: Electrical System

    ELECTRICAL SYSTEM 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. –...

  • Page 131: Installing The Battery

    ELECTRICAL SYSTEM 14.2 Installing the battery Main work – Slide the battery into the battery holder. Info The battery terminals must be at the rear. – Attach the positive cable and mount positive terminal cover – Position retaining bracket – Mount and tighten screws 601812-11 Guideline...

  • Page 132: 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 133 ELECTRICAL SYSTEM Info Even when there is no load on the battery, it still loses power steadily. The charging level and the method of charging are very important for the service life of the battery. Rapid recharging with a high charging current shortens the battery's service life. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves.
  • Page 134 ELECTRICAL SYSTEM 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 bat- tery, and to test the alternator. With this device, you cannot overcharge the battery. Info Never remove lid Charge the battery with a maximum of 10% of the capacity specified on the bat-...

  • Page 135: Changing The Main Fuse

    ELECTRICAL SYSTEM 14.4 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 –...

  • Page 136: Changing Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM – Remove a defective main fuse with needle nose pliers. – Install a new main fuse. Fuse (58011109130) ( p. 185) Info A reserve fuse is located in the starter relay. – Check the functioning of the electrical equipment. –...
  • Page 137 ELECTRICAL SYSTEM Main work – Open fuse box cover 601791-11 – 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...

  • Page 138: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 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. – Replace with a spare fuse of the right rating. Fuse (75011088010) ( p.
  • Page 139 ELECTRICAL SYSTEM Main work – Cover the fender with a cloth to protect it from damage. – Remove screws on both sides. – Tip the headlight mask forward. 601793-10 – Disconnect the connectors of turn signals and headlight – Remove the headlight mask. 601794-10...

  • Page 140: Installing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 14.7 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.

  • Page 141: Changing The Headlight Bulb

    ELECTRICAL SYSTEM – Position brake line guide . Mount and tighten screws Guideline Screw, headlight mask 5 Nm (3.7 lbf ft) 601793-11 Finishing work – Check the headlight setting. ( p. 143) 14.8 Changing the headlight bulb Note Damage to reflector Reduced brightness. –...
  • Page 142 ELECTRICAL SYSTEM Main work – Pull off connector – Take off protection cap of the headlight bulb. 600610-10 – Detach spring bar – Remove headlight bulb – Insert a new headlight bulb into the headlight housing. Headlight (H4 / socket P43t) ( p.

  • Page 143: Changing The Parking Light Bulb

    ELECTRICAL SYSTEM 14.9 Changing the parking light bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.

  • Page 144: Changing The Turn Signal Bulb

    ELECTRICAL SYSTEM – 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. 186) –...

  • Page 145: Checking The Headlight Setting

    ELECTRICAL SYSTEM Main work – Remove the screw on the rear of the turn signal housing. – Tilt headlamp diffuser forward carefully and take it off. – Press the turn signal bulb carefully into the socket, turn it counterclockwise by about 30°, and take it out of the socket.

  • Page 146: Adjusting The Headlight Range

    ELECTRICAL SYSTEM – The rider, with luggage and a passenger if applicable, now sits down on the motorcycle. – Switch on the low beam. – Check the headlight setting. For a ready-to-operate motorcycle with a rider, and with luggage and a passenger if applicable, the light-dark boundary must lie exactly on the lower mark.

  • Page 147: Cooling System

    COOLING SYSTEM 15.1 Cooling system The water pump in the engine forces the coolant to flow. The pressure in the cooling system resulting from heat is regulated by a valve in the radi- ator cap . The heat expansion causes the surplus coolant to flow into the compensating tank .
  • Page 148 COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.

  • Page 149: Checking The Coolant Level

    COOLING SYSTEM – 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. – Check the coolant level in the radiator. The radiator must be completely filled.
  • Page 150 COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.

  • Page 151: Draining The Coolant

    COOLING SYSTEM Alternative 2 Coolant (mixed ready to use) ( p. 193) – Mount the radiator cap. 15.4 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.

  • Page 152: Filling/Bleeding The Cooling System

    COOLING SYSTEM Finishing work – Install the engine guard. ( p. 99) 15.5 Filling/bleeding the cooling system Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor.
  • Page 153 COOLING SYSTEM – Refill the coolant. Alternative 1 Coolant ( p. 193) Alternative 2 Coolant (mixed ready to use) ( p. 193) – Fill the radiator completely with coolant. Mount radiator cap 601800-10 – Remove the cap from compensating tank and add coolant to the level shown in the figure.

  • Page 154: Tuning The Engine

    TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip backwards and forwards to ascertain the play in the throttle cable. Throttle cable play 3…...

  • Page 155: Adjusting The Engine Characteristic

    Main work – Move the handlebar to the straight-ahead position. – Use the KTM diagnostics tool to set the throttle stepper motor to the neutral position. – Loosen lock nut – Set the play in the throttle cable by turning adjusting screw...
  • Page 156 TUNING THE ENGINE – 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. –...

  • Page 157: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 16.4 Checking the basic position of the shift lever – Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the shift lever. Distance between shift lever and upper 10…...
  • Page 158 TUNING THE ENGINE – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gear- ing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure.

  • Page 159: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 17.1 Checking the engine oil level Info The engine oil level must be checked when the engine is warm. Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work –...

  • Page 160: Changing The Engine Oil And Filter, Cleaning The Oil Screens

    SERVICE WORK ON THE ENGINE 17.2 Changing the engine oil and filter, cleaning the oil screens – Drain the engine oil. p. 158) – Remove the oil filter. p. 159) – Clean the oil screens. p. 161) – Install the oil filter. p.

  • Page 161: Removing The Oil Filter

    SERVICE WORK ON THE ENGINE Main work – Place a suitable container under the engine. – Remove the oil drain plug with the magnet and seal ring. – Completely drain the engine oil. 100200-10 – Thoroughly clean the oil drain plug with a magnet. –...
  • Page 162 SERVICE WORK ON THE ENGINE Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Preparatory work – Place a suitable container under the engine. Main work –...

  • Page 163: Cleaning The Oil Screens

    SERVICE WORK ON THE ENGINE 17.5 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.
  • Page 164 SERVICE WORK ON THE ENGINE – Remove screw plug with oil screen and the O-rings. – Completely drain the remaining engine oil. – Thoroughly clean the parts and sealing area. 100206-10 – Position oil screen with the O-rings. – Mount and tighten screw plug with the O-ring.

  • Page 165: Installing The Oil Filter

    SERVICE WORK ON THE ENGINE 17.6 Installing the oil filter – Insert oil filters – Oil the O-rings of the oil filter covers. Mount oil filter covers – Mount and tighten the screws. Guideline Screw, oil filter cover 6 Nm (4.4 lbf ft) 100204-10 17.7 Filling up with engine oil...

  • Page 166: Adding Engine Oil

    SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
  • Page 167 SERVICE WORK ON THE ENGINE – Install and tighten the oil filler plug with the O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 168: Cleaning, Care

    CLEANING, CARE 18.1 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 pres- sure can cause malfunctions or destroy these parts.
  • Page 169 CLEANING, CARE – After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly. – Remove the plug from the exhaust system. Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake sys- tem.

  • Page 170: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE Universal oil spray ( p. 199) 18.2 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 aggressive road salt. If the vehicle was operated in road salt, clean it with cold water after riding.

  • Page 171: Storage

    0… 35 °C (32… 95 °F) direct sunshine – Store the vehicle in a dry location that is not subject to large fluctuations in tempera- ture. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the lift stand. ( p. 78)

  • Page 172: Preparing For Use After Storage

    STORAGE – Cover the motorcycle with a tarp or similar cover that is permeable to air. 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 173: Troubleshooting

    Coupling of fuel hose connection not Reconnect coupling of fuel hose connection. connected – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine has too little power. Air filter is very dirty Remove the air filter.
  • Page 174 Air in cooling system Fill/bleed the cooling system. p. 150) – FI warning lamp (MIL) lights/flashes Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine dies during the journey Lack of fuel Refuel. ( p.
  • Page 175 TROUBLESHOOTING Faults Possible cause Action – Battery discharged Ignition not switched off when vehicle Recharge the battery. p. 130) was parked – Battery is not charged by alternator Check the charging voltage. – Check the quiescent current. – Combination instrument shows nothing Fuse 1 blown Change the fuses of individual power consumers.

  • Page 176: Blink Code

    BLINK CODE Blink code FI of warning lamp (MIL) 02 FI warning lamp (MIL) flashes briefly 2x Error level condition Crankshaft position sensor - circuit fault Blink code FI of warning lamp (MIL) 06 FI warning lamp (MIL) flashes briefly 6x Error level condition Throttle position sensor circuit A - input signal too low Blink code FI of warning lamp...
  • Page 177 BLINK CODE Blink code FI of warning lamp (MIL) 14 FI warning lamp (MIL) flashes 1x long, 4x short Error level condition Ambient air pressure sensor - input signal too low Ambient air pressure sensor - input signal too high Blink code FI of warning lamp (MIL) 15 FI warning lamp (MIL) flashes 1x long, 5x short...
  • Page 178 BLINK CODE Blink code FI of warning lamp (MIL) 26 FI warning lamp (MIL) flashes 2x long, 6x short Error level condition Motor drive hall sensor - circuit fault Blink code FI of warning lamp (MIL) 37 FI warning lamp (MIL) flashes 3x long, 7x short Error level condition Ignition coil 1, cylinder 1 - circuit fault Blink code FI of warning lamp...
  • Page 179 BLINK CODE Blink code FI of warning lamp (MIL) 54 FI warning lamp (MIL) flashes 5x long, 4x short Error level condition Secondary air valve - short circuit to ground or open circuit Blink code FI of warning lamp (MIL) 58 FI warning lamp (MIL) flashes 5x long, 8x short Error level condition EPT motor drive relay permission - signal fault...
  • Page 180 BLINK CODE Blink code FI of warning lamp (MIL) 92 FI warning lamp (MIL) flashes 9x long, 2x short Error level condition Motor drive voltage (internal) - circuit fault...

  • Page 181: Technical Data

    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 Idle speed Coolant temperature: ≥ 70 °C (≥ 158 °F) 1,550… 1,650 rpm Control OHC, 4 valves controlled via rocker arm, chain drive Valve diameter, intake...

  • Page 182: Engine Tightening Torques

    TECHNICAL DATA 3rd gear 21:28 4th gear 21:23 5th gear 23:22 6th gear 23:20 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 224 W Spark plug NGK LKAR 8AI - 9 Spark plug electrode gap 0.9 mm (0.035 in) Cooling...
  • Page 183 TECHNICAL DATA ® Plug, vacuum connection 10 Nm (7.4 lbf ft) Loctite 243™ – Screw in alternator cover 10 Nm (7.4 lbf ft) ® Screw, alternator cover (chain shaft 10 Nm (7.4 lbf ft) Loctite 243™ through-hole) ® Screw, autodecompression 3…...
  • Page 184 TECHNICAL DATA – Screw, water pump cover 10 Nm (7.4 lbf ft) ® Screw, water pump wheel 10 Nm (7.4 lbf ft) Loctite 243™ ® Oil jet, piston cooling M6x0.75 4 Nm (3 lbf ft) Loctite 243™ – Screw plug, crankshaft clamp 20 Nm (14.8 lbf ft) ®...

  • Page 185: Capacities

    TECHNICAL DATA – Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) – Oil pressure regulator valve plug M12x1.5 20 Nm (14.8 lbf ft) ® Screw plug, oil channel M14x1.5 15 Nm (11.1 lbf ft) Loctite 243™ ® Engine case stud M16x1.5 25 Nm (18.4 lbf ft)

  • Page 186: Fuel

    TECHNICAL DATA 22.3.3 Fuel Total fuel tank capacity, approx. 12 l (3.2 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 195) Fuel reserve, approx. 2.5 l (2.6 qt.) 22.4 Chassis Frame Lattice frame made of chrome molybdenum steel tubing, powder- coated Fork WP Suspension 4860 MXMA...

  • Page 187: Electrical System

    TECHNICAL DATA Tire air pressure with passenger / fully loaded Front 2.0 bar (29 psi) Rear 2.2 bar (32 psi) Tire air pressure, offroad, single rider Front 1.5 bar (22 psi) Rear 1.5 bar (22 psi) Secondary drive ratio 15:45 Chain 5/8 x 1/4”...

  • Page 188: Tires

    Rear 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 22.7 Fork Fork part number 14.18.7L.10 Fork WP Suspension 4860 MXMA...

  • Page 189: Shock Absorber

    TECHNICAL DATA Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring length with preload spacer(s) 472 mm (18.58 in) Spring rate Soft 5.2 N/mm (29.7 lb/in) Medium (standard) 5.4 N/mm (30.8 lb/in) Hard...
  • Page 190 TECHNICAL DATA Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload 20 mm (0.79 in) Spring rate Medium (standard) 80 N/mm (457 lb/in) Hard...

  • Page 191: Chassis Tightening Torques

    TECHNICAL DATA 22.9 Chassis tightening torques – Screw, chain guard EJOT 2 Nm (1.5 lbf ft) – Screw, combination instrument EJOT 1 Nm (0.7 lbf ft) – Screw, license plate holder, bottom EJOT 3 Nm (2.2 lbf ft) – Screw, side cover on spoiler EJOT 1 Nm (0.7 lbf ft) –...
  • Page 192 TECHNICAL DATA – Remaining nuts, chassis 10 Nm (7.4 lbf ft) – Remaining screws on fuel tank 5 Nm (3.7 lbf ft) – Remaining screws, chassis 10 Nm (7.4 lbf ft) – Screw connection, foot brake cylinder 10 Nm (7.4 lbf ft) –...
  • Page 193 TECHNICAL DATA – Remaining screws, chassis 25 Nm (18.4 lbf ft) – Screw, bottom triple clamp 12 Nm (8.9 lbf ft) – Screw, chain sliding piece 15 Nm (11.1 lbf ft) ® Screw, connection lever on frame 30 Nm (22.1 lbf ft) Loctite 243™...
  • Page 194 TECHNICAL DATA ® Engine carrying screw 45 Nm (33.2 lbf ft) Loctite 243™ – Remaining nuts, chassis 45 Nm (33.2 lbf ft) – Remaining screws, chassis 45 Nm (33.2 lbf ft) ® Screw, bottom shock absorber 45 Nm (33.2 lbf ft) Loctite 243™...

  • Page 195: Substances

    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 correspond- ing properties. KTM recommends Castrol and Motorex ® products. Supplier Castrol –...
  • Page 196 200) (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 197 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 ® –...
  • Page 198 SUBSTANCES Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).

  • Page 199: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Protect & Shine...
  • Page 200 AUXILIARY SUBSTANCES Long-life grease Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Bike Grease 2000 Motorcycle cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Moto Clean 900 Off-road chain spray Guideline – KTM recommends Motorex ®...
  • Page 201 AUXILIARY SUBSTANCES Universal oil spray Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Joker 440 Synthetic...

  • Page 202: 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 203: Index

    INDEX front brake, checking ......104 INDEX rear brake, changing ......113 rear brake, checking .
  • Page 204 INDEX Combination instrument Engine characteristic clock, setting ....... . 38 adjusting .
  • Page 205 INDEX removing ........136 Fork ........compression damping, adjusting .
  • Page 206 INDEX Operating substances ......19 Riding ........starting off .
  • Page 207 INDEX Spoke tension Troubleshooting ......171-173 checking ........126 Turn signal bulb Starting .
  • Page 208 *3211952en* 3211952en 11/2012 KTM-Sportmotorcycle AG Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com...

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