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REPAIR MANUAL
2008
690 SMC EU
690 SMC AUS/UK
690 SMC USA
Article no. 3206042en

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Table of Contents

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   Summary of Contents for KTM 2008 690 SMC EU

  • Page 1 REPAIR MANUAL 2008 690 SMC EU 690 SMC AUS/UK 690 SMC USA Article no. 3206042en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.
  • Page 4: Table Of Contents

    CONTENTS Filling the damper with nitrogen ........45 CONTENTS MEANS OF REPRESENTATION ..........5 Installing the spring............45 IMPORTANT NOTES ............6 05/EXHAUST ..............47 LOCATION OF SERIAL NUMBERS ........7 Removing the exhaust manifold ........47 Chassis number/type label (690 SMC EU, 690 SMC AUS/UK)............
  • Page 5 CONTENTS Changing the rear brake fluid.......... 80 Measuring axial clearance of crankshaft and balancer shaft ................112 14/LIGHT SYSTEM, INSTRUMENTS ........82 Cylinder - Nikasil ® coating ..........112 Setting kilometers or miles ..........82 Checking/measuring the cylinder........113 Setting the clock ............82 Checking/measuring the piston ........
  • Page 6 CONTENTS Installing the oil filter ..........144 Page 3 of 10............... 188 Installing gear position sensor........145 Page 4 of 10............... 190 Installing the spacer ............ 145 Page 5 of 10............... 192 Installing oil screens ............ 146 Page 6 of 10............... 194 Installing alternator cover ..........
  • Page 7: Means Of Representation

    MEANS OF REPRESENTATION Symbols used The symbols used are explained in the following. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Identifies a page reference (more information is provided on the specified page). Indicates information with more details or tips.
  • Page 8: Important Notes

    Warranty The work prescribed in the service plan must only be carried out in an authorized KTM workshop and confirmed in the service record; otherwise all warranty claims will be disregarded. No warranty claim can be met for damage resulting from manipulation and/or other changes to the vehicle.
  • Page 9: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS Chassis number/type label (690 SMC EU, 690 SMC AUS/UK) The chassis number is stamped on the right of the steering head.  The type label is on the right of the frame behind the steering head. ...
  • Page 10: Fork Part Number

    LOCATION OF SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub.  600480-10 Shock absorber part number The shock absorber part number is on the right of the shock absorber. ...
  • Page 11: Motorcycle

    MOTORCYCLE Raising the motorcycle with the rear wheel stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Insert the adapter into the rear wheel stand and screw into the swingarm on both sides.
  • Page 12: Raising The Motorcycle With The Work Stand

    MOTORCYCLE Raising the motorcycle with 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. – Mount the special tool on the footrest. Work stand adapter (75029036000) ( p.
  • Page 13: Starting

    MOTORCYCLE Starting Danger Danger of poisoning Exhaust gases are poisonous 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 14: 01/fork, Triple Clamp

    01/FORK, TRIPLE CLAMP Adjusting compression damping of fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn adjusting screws clockwise until they stop.  Info The adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs.
  • Page 15: Cleaning The Dust Boots Of The Fork Legs

    01/FORK, TRIPLE CLAMP Cleaning the dust boots of the fork legs – Jack up the motorcycle and secure it against falling over. The front wheel is no longer in contact with the ground and the fork legs are no longer under tension. –...
  • Page 16: Removing Fork Legs

    01/FORK, TRIPLE CLAMP Removing fork legs – Raise the motorcycle with the work stand. ( p. 10) – Tie the rear of the vehicle down. – Remove screws and spacers   – Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc.
  • Page 17: Installing The Fork Legs

    01/FORK, TRIPLE CLAMP – Loosen the screws of the triple clamp. Remove the fork legs from the bottom.  201379-10 Installing the fork legs – Slide the fork legs into the triple clamps on both sides. Info The bleeder screws must face forwards. The topmost milled groove in the fork leg must be flush with the top edge of the upper triple clamp.
  • Page 18: Servicing The Fork

    01/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.
  • Page 19: Disassembling The Fork Legs

    01/FORK, TRIPLE CLAMP – Disassemble the fork legs. ( p. 17) – Check the fork legs. ( p. 20) – Assemble the fork legs. ( p. 21) 201240-01 Disassembling the fork legs 5.10 Info These operations are the same on both fork legs. Condition The fork legs have been removed.
  • Page 20 01/FORK, TRIPLE CLAMP – Release the fork leg and clamp it with the axle clamp. Info Use soft jaws. 200661-01 – Push the outer tube downward. – Pull the spring downwards. Mount the special tool on the hexagon. Open-end wrench (T14032) ( p.
  • Page 21 01/FORK, TRIPLE CLAMP – Clamp the fork leg with the axle clamp. – Remove screws of the axle clamp.  200662-01 – Loosen screw of the cartridge and remove it with the sealing ring.  Info Place a container underneath to catch any oil that may run out. 200667-10 –...
  • Page 22: Checking The Fork Legs

    01/FORK, TRIPLE CLAMP – Heat up the outer tube in area of the lower sliding bushings.  Guideline 50 °C (122 °F) – Pull the outer tube of the fork off of the inner tube with a jerk. Info The lower sliding bushing must be pulled from its bearing seat.
  • Page 23: Assembling The Fork Legs

    01/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. »...
  • Page 24 01/FORK, TRIPLE CLAMP – Grease and push on seal ring  Lubricant (T511) ( p. 206) Info Sealing ring downward, open side upward. – Push on support ring  – Remove the special tool. – Sand the edges of the sliding bushes with 600-grain sandpaper, then clean and grease them.
  • Page 25 01/FORK, TRIPLE CLAMP – Install dust boot  200655-11 – Grease the O-ring of valve of the rebound damping.  Lubricant (T158) ( p. 206) – Mount valve of the rebound damping with the spring on adjusting tube   –...
  • Page 26 01/FORK, TRIPLE CLAMP – Clamp the fork vertically. – Fill it with fork oil. Fork oil per fork 634 ml Fork oil (SAE 5) ( p. 205) (21.44 fl. oz.) Info Pull out and push in the piston rod completely a few times to remove air from the cartridge.
  • Page 27: Checking The Steering Head Bearing Play

    01/FORK, TRIPLE CLAMP – Push the outer tube upward. – Clamp the fork in the area of the lower triple clamp. Clamping stand (T1403S) ( p. 219) – Grease the O-ring of the screw cover. Lubricant (T511) ( p. 206) –...
  • Page 28: Adjusting The Steering Head Bearing Play

    01/FORK, TRIPLE CLAMP – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: –...
  • Page 29: 02/handlebar, Instruments

    02/HANDLEBAR, INSTRUMENTS 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. ...
  • Page 30: Adjusting The Play In The Throttle Cable

    28) Adjusting the play in the throttle cable – Move the handlebar to the straight-ahead position. – Use the KTM diagnostics tool to set the motor drive to the basic position. – Loosen counter nut  – Set the play in the throttle cable by turning the adjusting screw ...
  • Page 31: 04/shock Absorber, Swingarm

    04/SHOCK ABSORBER, SWINGARM Adjusting the high-speed compression damping of the shock absorber Danger 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 can be seen during the fast compression of the shock absorber. –...
  • Page 32: Adjusting The Rebound Damping Of The Shock Absorber

    04/SHOCK ABSORBER, SWINGARM Adjusting the rebound damping of the shock absorber Danger 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.
  • Page 33: Checking The Riding Sag Of The Shock Absorber

    04/SHOCK ABSORBER, SWINGARM Checking the riding sag of the shock absorber – Measure distance of rear wheel unloaded. ( p. 30)  – 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.
  • Page 34: Adjusting The Riding Sag

    04/SHOCK ABSORBER, SWINGARM Adjusting the riding sag – Remove the shock absorber. ( p. 32) – After removing the shock absorber, clean it thoroughly. – Choose and mount a suitable spring. Guideline Spring rate Soft 80 N/mm (457 lb/in) Medium (standard) 85 N/mm (485 lb/in) Hard 90 N/mm (514 lb/in)
  • Page 35: Installing The Shock Absorber

    04/SHOCK ABSORBER, SWINGARM – Loosen screw  – Remove screw  – Remove screw  300565-10 – Swing the rear end upwards. – Lift shock absorber upwards and remove.  300566-10 Installing the shock absorber 7.10 – Swing the rear end upwards and insert shock absorber from above.
  • Page 36: Servicing The Shock Absorber

    04/SHOCK ABSORBER, SWINGARM – Mount and tighten screw  Guideline Screw, fuel tank, bottom 20 Nm (14.8 lbf ft) – Repeat the operation on the opposite side. 300564-11 – Lift the rear fairing. – Mount and tighten screws  Guideline Screw, main silencer 25 Nm Loctite...
  • Page 37: Removing The Spring

    04/SHOCK ABSORBER, SWINGARM Removing the spring 7.12 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.
  • Page 38: Disassembling The Piston Rod

    04/SHOCK ABSORBER, SWINGARM – Press in seal ring retainer . Remove lock ring   Info Do not scratch the inner surface. 300585-10 – Remove screw . Drain the oil.  300586-10 – Remove the piston rod. Drain the remaining oil. 300587-10 –...
  • Page 39: Checking The Damper

    04/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 ...
  • Page 40: Removing The Heim Joint

    04/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 ≤...
  • Page 41: Installing The Heim Joint

    04/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. 217) 200580-10 Installing the heim joint 7.17 –...
  • Page 42: Assembling The Piston Rod

    04/SHOCK ABSORBER, SWINGARM Assembling the piston rod 7.18 – Check the damper. ( p. 37) – Clamp the piston rod with the heim joint in a vise. – Mount rubber buffer and locking cap   300543-11 – Position special tool on the piston rod.
  • Page 43: Assembling The Damper

    04/SHOCK ABSORBER, SWINGARM Assembling the damper 7.19 – Assemble the piston rod. ( p. 40) – Position membrane  – Mount and tighten membrane cover  – Mount lock ring  300590-10 – Push the spring and sleeve onto the compression damping adjuster. Attach the pis- ton.
  • Page 44 04/SHOCK ABSORBER, SWINGARM – Mount locking cap of the damper cartridge.  – Bleed and fill the damper. ( p. 43) – Fill the damper with nitrogen. ( p. 45) 300594-10 Alternative 1 – Turn the adjusting screw clockwise with a screwdriver up to the last percep- ...
  • Page 45: Bleeding And Filling The Damper

    04/SHOCK ABSORBER, SWINGARM Bleeding and filling the damper 7.20 Info Before working with the vacuum pump, be sure to read the operating instructions carefully. Completely open the adjusters of the rebound and compression damping. – Remove the screw of the filling port. –...
  • Page 46 04/SHOCK ABSORBER, SWINGARM – When the pressure gauge reaches the specified value, turn the Damper control  lever to Vacuum. Guideline 3 bar The pressure gauge falls to the specified value. 0 bar 200269-10 – When the pressure gauge reaches the specified value, turn the Oil reservoir con- ...
  • Page 47: Filling The Damper With Nitrogen

    04/SHOCK ABSORBER, SWINGARM – Mount and tighten screw  Guideline Filling port screw M10x1 14 Nm (10.3 lbf ft) 300600-10 Filling the damper with nitrogen 7.21 – Clamp the damper in the vise using soft jaws. – Mount special tool on the damper connector.
  • Page 48 04/SHOCK ABSORBER, SWINGARM Guideline Spring rate Soft 80 N/mm (457 lb/in) Medium (standard) 85 N/mm (485 lb/in) Hard 90 N/mm (514 lb/in) – Tension the spring with the special tool. Spring compressor (T101S) ( p. 217) – Install the spring retainer ...
  • Page 49: 05/exhaust

    05/EXHAUST Removing the exhaust 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. – Remove the air filter box. ( p. 51) –...
  • Page 50: Removing The Main Silencer

    05/EXHAUST – Position the spacer. – Position the manifold at the front with the seals. – Mount and tighten nuts  Guideline Nut, manifold on cylinder 25 Nm Copper paste head (18.4 lbf ft) 300208-11 – Position the exhaust clamp. –...
  • Page 51: Installing The Main Silencer

    05/EXHAUST – Loosen screw  302045-10 – Remove screws  – Lift the rear fairing. 302046-10 – Remove screws  – Remove the main silencer. 302047-10 Installing the main silencer – Position the main silencer. – Mount and tighten screws ...
  • Page 52 05/EXHAUST – Mount and tighten screws  Guideline Rear fairing screw 2 Nm (1.5 lbf ft) 302046-11...
  • Page 53: 06/air Filter

    06/AIR FILTER Removing the air filter – Remove the seat. ( p. 54) – Remove screws . Remove filter box top   100285-10 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. –...
  • Page 54: Installing The Air Filter Box

    06/AIR FILTER – Remove screws  300203-10 – Remove screws  300204-10 – Loosen hose clip  300205-10 – Raise the air filter box at the rear. – Loosen the spring-loaded band-type clamp with the special tool and detach bleed hose ...
  • Page 55 06/AIR FILTER – Mount and tighten screws  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 300204-10 – Mount and tighten screws  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 300203-11 – Position the voltage regulator. – Mount and tighten screws ...
  • Page 56: 07/fuel Tank, Seat, Trim

    07/FUEL TANK, SEAT, TRIM Opening filler cap 10.1 – Lift the cover of the filler cap and insert the ignition key.  – Turn the ignition key 90° counterclockwise and remove the filler cap. Info The filler cap has a tank air vent system. 100227-10 Closing filler cap 10.2...
  • Page 57: Mounting The Side Cover

    07/FUEL TANK, SEAT, TRIM Mounting the side cover 10.6 – Attach the side cover in area and engage it in area   – Mount and tighten screws  Guideline Screw, side cover 2 Nm (1.5 lbf ft) – Repeat the operation on the opposite side. –...
  • Page 58: Changing The Fuel Filter

    07/FUEL TANK, SEAT, TRIM – Select "Fuel pump relay function test". – Press "Continue". – In the KTM diagnostics tool, read the information page and start the actuator test with "Continue". Guideline Maximum duration of actuator test 3 min –...
  • Page 59 07/FUEL TANK, SEAT, TRIM – Lift the rear fairing. – Remove screws  300563-10 – Remove screw  – Repeat the operation on the opposite side. – Swing the rear end upwards and secure it. 300564-10 – Remove screws  –...
  • Page 60 07/FUEL TANK, SEAT, TRIM – Mount fuel filter  Arrow points away from the fuel pump.  – Mount hose clamps  Hose clamp pliers (60029057000) ( p. 210) 302608-11 – Position the fuel pump. – Mount and tighten screws ...
  • Page 61: 09/front Wheel

    09/FRONT WHEEL Removing front wheel 11.1 – Raise the motorcycle with the rear wheel stand. ( p. 9) – Raise the motorcycle with the front wheel stand. ( p. 9) – Remove screws and spacers   – Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc.
  • Page 62: Checking The Tire Air Pressure

    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.
  • Page 63: Checking The Brake Discs

    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 five years. »...
  • Page 64: 10/rear Wheel

    10/REAR WHEEL Removing rear wheel 12.1 – Raise the motorcycle with the rear wheel stand. ( p. 9) – Press the brake caliper by hand on to the brake disc in order to press back the brake piston. – Remove nut .
  • Page 65: Checking The Chain Tension

    10/REAR WHEEL – Tighten nut  Guideline Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft) – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. –...
  • Page 66: Adjusting Chain Guide

    10/REAR WHEEL – 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 ...
  • Page 67: Cleaning The Chain

    10/REAR WHEEL – Shift into neutral; pull the lower chain section with specified weight  Guideline Weight of chain wear measurement 15 kg (33 lb.) – 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.
  • Page 68: Checking The Rear Hub Rubber Dampers

    10/REAR WHEEL – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( p. 206) – After drying, apply chain spray. Chain lube for road use ( p.
  • Page 69: Checking The Rim Run-out

    10/REAR WHEEL » If the spoke tensions differ: – Correct the spoke tension. Checking the rim run-out 12.10 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.
  • Page 70: 11/wiring Harness, Battery

    11/WIRING HARNESS, BATTERY Removing the battery 13.1 Warning Risk of injury Battery acid and battery gases cause serious cauterization. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...
  • Page 71: Connecting 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 72: Checking The Charging Voltage

    11/WIRING HARNESS, BATTERY – 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.
  • Page 73: Changing Fuses Of Individual Power Consumers

    11/WIRING HARNESS, BATTERY – Switch off all power consumers and switch off the engine. – Remove the seat. ( p. 54) – Remove protection covers  600604-10 – Remove a defective main fuse with needle nose pliers.  – Install a new main fuse. Fuse (58011109130) ( p.
  • Page 74: Adjusting The Engine Characteristic

    11/WIRING HARNESS, BATTERY Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. – Replace with a spare fuse of the right rating. Fuse (75011088010) ( p.
  • Page 75: 13/brake System

    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.
  • Page 76: Adjusting The Basic Position Of The Hand Brake Lever

    13/BRAKE SYSTEM – Remove the front brake linings. – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws  – Remove cover with membrane   – Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir.
  • Page 77: Adding Front Brake Fluid

    13/BRAKE SYSTEM Adding front brake fluid 14.5 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.
  • Page 78: Checking The Rear Brake Linings

    13/BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – 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.
  • Page 79: Changing Rear Brake Linings

    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.
  • Page 80: Checking The Free Travel Of Foot Brake Lever

    13/BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake   caliper support are seated correctly. 400419-10 – Insert the brake pads, insert the bolt and mount the split 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 81: Checking Rear Brake Fluid Level

    13/BRAKE SYSTEM – Remove screws on foot brake cylinder   – To adjust the basic position of the foot brake lever individually, loosen nut  turn screw accordingly.  Info The range of adjustment is limited. The screw must be screwed into the footrest bracket by at least four turns.
  • Page 82: Changing The Rear Brake Fluid

    13/BRAKE SYSTEM 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. 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.
  • Page 83 13/BRAKE SYSTEM – Add brake fluid to the MAX mark. Brake fluid DOT 4 / DOT 5.1 ( p. 204) – Mount the screw cap with the washer and membrane. – Activate the foot brake lever until there is a firm pressure point. Info Clean up overflowed or spilt brake fluid immediately with water.
  • Page 84: 14/light System, Instruments

    14/LIGHT SYSTEM, INSTRUMENTS Setting kilometers or miles 15.1 Info If you change the unit, the value ODO 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 in the position (690 SMC EU, 690 SMC AUS/UK) (690 SMC USA).
  • Page 85: Combination Instrument - Setting/resetting Trip 2

    14/LIGHT SYSTEM, INSTRUMENTS Combination instrument - setting/resetting TRIP 2 15.4 Info The TRIP 2 trip counter is always running and counts up to 999.9. The trip counter can be used to measure the distance covered during trips or between two refueling stops. After the value 999.9 is reached, the trip counter starts at 0.0 again.
  • Page 86: Checking The Headlight Setting

    14/LIGHT SYSTEM, INSTRUMENTS Checking the headlight setting 15.6 – Stand the vehicle upright on a horizontal surface in front of a light wall and make a 0 0 A mark at the height of the center of the low beam headlight. –...
  • Page 87: Installing The Headlight Mask With The Headlight

    14/LIGHT SYSTEM, INSTRUMENTS Installing the headlight mask with the headlight 15.9 – Connect the connectors of headlight and flasher lights   – Check lighting function. 100294-11 – Remove the cloth from the fender, attach the headlight mask to points on the ...
  • Page 88: Changing The Headlight Bulb

    14/LIGHT 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.
  • Page 89 14/LIGHT SYSTEM, INSTRUMENTS – Insert the screw and turn it counterclockwise first until it engages in the thread. Tighten the screw slightly. – Check the flasher system function.
  • Page 90: 30/engine

    30/ENGINE Removing the engine 16.1 – Raise the motorcycle with the work stand. ( p. 10) – Disconnect the battery. ( p. 68) – Remove the exhaust manifold. ( p. 47) – Drain the coolant. ( p. 149) – Loosen the spring-loaded band-type clamp using the special tool.
  • Page 91 30/ENGINE – Take off the clutch push rod. – Unscrew the electrical connection from the starter motor.  – Remove ground wire from the starter motor.  300216-10 – Loosen hose clip  – Pull off the throttle valve body from the rear. 300217-10 –...
  • Page 92: Installing The Engine

    30/ENGINE – Position the floor jack under the engine and fix it using the special tool. Floor jack attachment (75029055000) ( p. 215) 300222-10 – Remove nut of the lower engine bracket. Remove the screw.  300223-10 – Remove screw of the swingarm pivot.
  • Page 93 30/ENGINE – Install the screw and nut of the lower engine bracket, but do not tighten them  yet. 300223-11 – Remove the floor jack with the special tool. Floor jack attachment (75029055000) ( p. 215) 300222-10 – Position the engine bearer. –...
  • Page 94 30/ENGINE – Reconnect plug connectors of the gear position sensor, the crankshaft position  sensor and the alternator. 300218-11 – Position the throttle valve body. – Position and tighten hose clip  300217-11 – Position the electrical connection on the starter motor. Mount and tighten screw. ...
  • Page 95 Remove the motorcycle from the work stand. ( p. 10) – 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.
  • Page 96: 30/disassembling The Engine

    30/DISASSEMBLING THE ENGINE Clamping engine into engine work stand 17.1 – Mount special tool on engine work stand   Engine work stand (61229001000) ( p. 211) Support for engine work stand (75012001060) ( p. 212) Holder for engine work stand (75012001070) ( p.
  • Page 97: Removing The Alternator Cover

    30/DISASSEMBLING THE ENGINE Removing the alternator cover 17.5 – Remove screws . Take off the alternator cover.  – Remove dowels. 300004-10 Removing spacer 17.6 – Remove the spacer of the countershaft.  302124-10 Removing gear position sensor 17.7 – Remove screws.
  • Page 98: Removing Thermostat

    30/DISASSEMBLING THE ENGINE – Remove screws. Remove the oil filter cover with the O-ring.  – Pull the oil filter element out of the oil filter case.  Circlip pliers reverse (51012011000) ( p. 208) 300011-10 Removing thermostat 17.9 – Remove screws.
  • Page 99: Removing Clutch Cover

    30/DISASSEMBLING THE ENGINE – Remove screw . Take off the water pump wheel   – Take off the water pump cover seal. Info Do not lose the centering pins. 300013-10 – Remove the shaped washer  300014-10 Removing clutch cover 17.12 –...
  • Page 100: Removing Timing Chain Tensioner

    30/DISASSEMBLING THE ENGINE Removing timing chain tensioner 17.15 – Remove screw . Take off the seal ring.  – Pull out timing chain tensioner  300017-10 Removing camshafts 17.16 – Remove screw . Take off the camshaft support plate  ...
  • Page 101: Removing Rotor

    30/DISASSEMBLING THE ENGINE – Remove piston pin retainer  – Remove the piston pin. – Take off the cylinder with the piston. – Push the piston upward out of the cylinder. Info If no other work is required on the cylinder and the piston, you can leave the piston in the cylinder.
  • Page 102: Removing Timing Chain And Timing Chain Sprocket

    30/DISASSEMBLING THE ENGINE – Hold the timing chain securing guide tight and pull the timing chain tensioning rail out of the timing chain securing guide.  – Take out the timing chain tensioning rail upwards through the chain shaft. – Remove the timing chain securing guide ...
  • Page 103 30/DISASSEMBLING THE ENGINE – Loosen the screws diagonally and remove them with their spring retainers and  clutch springs. – Remove the pressure cap  300052-10 – Remove the pressure piece  – Bend up the lock washer  300053-10 –...
  • Page 104: Removing Primary Gear

    30/DISASSEMBLING THE ENGINE Removing primary gear 17.24 – Plug the special tool into the crankshaft. Protection cover (75029090000) ( p. 215) – Screw the special tool on to the primary gear   Extractor (75029021000) ( p. 212) – Hold it using the special tool and pull off the primary gear by turning the screw in. –...
  • Page 105: Removing Locking Lever

    30/DISASSEMBLING THE ENGINE Removing locking lever 17.28 – Remove screw  – Take off locking lever with the sleeve and spring.  300069-10 Removing oil pumps 17.29 – Remove the lock washers and normal washers from both oil pumps.  ...
  • Page 106: Removing Crankshaft And Balancer Shaft

    30/DISASSEMBLING THE ENGINE – Install the special tool with suitable screws.  Extractor (75029048000) ( p. 214) Info Use the 750 drill hole. – Pull off the section of the engine case. Info 300076-10 Do not tension the section of the engine case. The balancer shaft and the main shaft have a stop disk, these usually stick to the bearing.
  • Page 107 30/DISASSEMBLING THE ENGINE – Remove shift forks  Info Ensure that the pins remain in place. 300081-10 – Remove the lock ring and the stop disk.  300082-10 – Pull both transmission shafts out of the bearing seats together.  Info The stop disk of the countershaft usually sticks to the bearing.
  • Page 108: 30/engine - Work On Individual Parts

    30/ENGINE - WORK ON INDIVIDUAL PARTS Work on the right section of the engine case 18.1 – Remove oil jet  – Remove bearing locks of the main shaft bearing , of the countershaft bearing   and of the shift drum bearing ...
  • Page 109: Work On The Left Section Of The Engine Case

    30/ENGINE - WORK ON INDIVIDUAL PARTS Guideline Oil jet, conrod lubrication 2 Nm Loctite ® 243™ (1.5 lbf ft) – Blow compressed air through all oil holes and check that they are clear. – Position the cover plate . Mount and tighten the screws. ...
  • Page 110: Work On The Clutch Cover

    30/ENGINE - WORK ON INDIVIDUAL PARTS 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 ring; otherwise, the bearings will be damaged when they are pressed in. –...
  • Page 111: Removing Crankshaft Bearing Inner Ring

    30/ENGINE - WORK ON INDIVIDUAL PARTS Removing crankshaft bearing inner ring 18.4 – Fix the crankshaft with special tools in the vise.   Upper part, pressing-out tool (75029047050) ( p. 214) Under part, pressing-out tool (75029047051) ( p. 214) 300135-10 –...
  • Page 112 30/ENGINE - WORK ON INDIVIDUAL PARTS – Press in the new crank pin as far as possible.  Info The crank pin must be pressed in so that oil hole is aligned with oil  hole  If the oil holes are not correctly aligned, the conrod bearing will not be sup- plied with oil.
  • Page 113: Checking Crankshaft Run-out At Bearing Pin

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking crankshaft run-out at bearing pin 18.7 – Position the crankshaft on a roller block. – Rotate the crankshaft slowly. – Check the crankshaft run-out at both bearing pins. ≤ 0.10 mm (≤ 0.0039 in) Crankshaft run-out at bearing pin »...
  • Page 114: Measuring Axial Clearance Of Crankshaft And Balancer Shaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS Measuring axial clearance of crankshaft and balancer shaft 18.10 – Insert the crankshaft and balancer shaft in the right engine casing. Info Do not forget the dowels. – Mount the left engine casing. – Mount and tighten the screws.
  • Page 115: Checking/measuring The Cylinder

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking/measuring the cylinder 18.12 – Check the O-ring of the chain adjuster for damage and wear. » If there is damage or wear: – Replace the O-ring. – Check the cylinder bearing surface for damage. »...
  • Page 116: Checking Piston Ring End Gap

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Clean the piston ring groove. Use an old piston ring to clean the piston ring groove. – Check the piston rings for damage. » If the piston ring is damaged: – Change the piston ring. Info Mount the piston ring with the marking facing upward.
  • Page 117: Checking Piston/cylinder Mounting Clearance

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking piston/cylinder mounting clearance 18.15 – Check/measure the cylinder. ( p. 113) – Check/measure the piston. ( p. 113) – The smallest piston/cylinder mounting clearance is the result of the smallest cylinder bore diameter minus the largest piston diam- eter.
  • Page 118: Preparing Timing Chain Tensioner For Installation

    30/ENGINE - WORK ON INDIVIDUAL PARTS – When assembling, first connect the autodecompression spring and then insert the screw through the autodecompression weight. The arm of the autodecompression spring is long enough to pass right  through the autodecompression weight. –...
  • Page 119: Checking Timing Assembly

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking timing assembly 18.19 – Clean all parts well. 0 0 1 0 0 5 – Check the timing chain gear / timing chain sprocket for damage and wear.  » If there is damage or wear: –...
  • Page 120: Removing Valves

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Remove the small camshaft bearing using the special tool.  Insert for bearing puller (15112018100) ( p. 208) Bearing puller (15112017000) ( p. 208) 300228-10 – Press in the small camshaft bearing as far as possible using the special tool ...
  • Page 121: Checking Valves

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking valves 18.23 – Check the run-out at the valve plate. Valve - run-out ≤ 0.05 mm (≤ 0.002 in) On the valve plate » If the measured value does not equal the specified value: –...
  • Page 122: Installing Valves

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Check the sealing area of the cylinder for distortion using a straight edge and the special tool. Feeler gauge (59029041100) ( p. 210) ≤ 0.10 mm (≤ 0.0039 in) Cylinder/cylinder head - sealing area distortion »...
  • Page 123: Installing Rocker Arm

    30/ENGINE - WORK ON INDIVIDUAL PARTS Installing rocker arm 18.28 – Position the rocker arm and push in the rocker arm shafts   Info Make sure that the tapped hole of the rocker arm shaft is positioned facing outwards. The small drill hole and the flat surface must point upwards.
  • Page 124: Checking The Clutch

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the clutch 18.30 – Dismantle the antihopping clutch. ( p. 121) 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...
  • Page 125: Preassembling Antihopping Clutch

    30/ENGINE - WORK ON INDIVIDUAL PARTS » If the intermediate discs are not level or are pitted: – Replace all intermediate discs. – Check clutch facing discs for discoloration and scoring.  » If there is discoloration or scoring: – Change all clutch facing discs.
  • Page 126: Checking Shift Mechanism

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking shift mechanism 18.32 – 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 the idler/fixed gear pair. 0 0 4 0 0 1 –...
  • Page 127: Disassembling The Main Shaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS Disassembling the main shaft 18.34 0303 300127-03 – 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  ...
  • Page 128: Checking The Transmission

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Remove stop disk and the first-gear idler gear   – Remove needle bearing and stop disk   – Remove the fifth-gear sliding gear and lock ring   – Remove stop disk and the third-gear idler gear ...
  • Page 129: Assembling The Main Shaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS » If the fixed gear does not move easily: – Change the fixed gear or the main shaft. – Check fixed gears for smooth operation in the profile of countershaft   » If the fixed gear does not move easily: –...
  • Page 130: Assembling Countershaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS Assembling countershaft 18.38 Info Use new lock rings in every repair job. – Oil all parts carefully before assembling. – Check the transmission. ( p. 126) 300128-02 – Fix the countershaft in the vise with the geared end facing downward. Guideline Use soft jaws –...
  • Page 131: Checking Electric Starter Drive

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking electric starter drive 18.39 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. –...
  • Page 132: Checking Freewheel

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Compress the expansion ring and remove it, using suitable pliers.  – Take the freewheel out of the primary gear.  300128-10 Checking freewheel 18.41 – Insert the freewheel gear in the primary gear , turning the primary gear clock- ...
  • Page 133 30/ENGINE - WORK ON INDIVIDUAL PARTS – Insert the lock ring into the groove with suitable pliers and check that it is  seated correctly. 300127-11...
  • Page 134: 30/assembling The Engine

    30/ASSEMBLING THE ENGINE Installing transmission shafts 19.1 – Clamp the right section of the engine case. Holder for engine work stand (75012001070) ( p. 212) Support for engine work stand (75012001060) ( p. 212) Engine work stand (61229001000) ( p. 211) –...
  • Page 135: Installing Crankshaft And Balancer Shaft

    30/ASSEMBLING THE ENGINE Installing crankshaft and balancer shaft 19.2 – Mount the special tool on the alternator side of the crankshaft.  Mounting sleeve (75029080000) ( p. 215) – Mount the special tool on the balancer shaft.  Mounting sleeve (58529005000) ( p.
  • Page 136: Installing Oil Pumps

    30/ASSEMBLING THE ENGINE Installing oil pumps 19.4 – Install pins and internal rotors on both oil pump shafts. – Mount external rotors in the engine case. The marking is not visible after mounting. – Mount the oil pump shafts with internal rotors ...
  • Page 137: Installing Shift Shaft

    30/ASSEMBLING THE ENGINE – Release the locking lever. – Mount and tighten screw  Guideline Screw, shift drum locating 10 Nm Loctite ® 243™ (7.4 lbf ft) 300067-11 Installing shift shaft 19.7 – Slide shift shaft with the washer into the bearing seat. ...
  • Page 138: Installing Clutch Cage

    30/ASSEMBLING THE ENGINE Installing clutch cage 19.10 – Install supporting plate and needle bearing   300057-10 – Install the clutch cage  Info Turn the clutch cage and oil pump gear wheels backwards and forwards slightly to help them mesh more easily. –...
  • Page 139: Installing Crankshaft Position Sensor

    30/ASSEMBLING THE ENGINE – Insert the pressure piece  300061-10 – Place the pressure cap on. – Install and tighten the screws with the spring retainers and clutch springs.  Guideline Screw, clutch spring 6 Nm (4.4 lbf ft) – Remove the special tool.
  • Page 140: Installing Timing Chain Rails

    30/ASSEMBLING THE ENGINE Installing timing chain rails 19.13 – Position the timing chain securing guide  Info The cable of the crankshaft position sensor must be laid in the cable chan- nel of the timing chain securing guide. – Thread in the timing chain tensioning rail from above.
  • Page 141: Setting Engine To Top Dead Center

    30/ASSEMBLING THE ENGINE Setting engine to top dead center 19.16 – Set the crankshaft to top dead center and lock it with the special tool  Engine blocking screw (77329010000) ( p. 216) 300025-10 Installing piston 19.17 – Shift the joint of the piston rings by 120°. –...
  • Page 142: Installing Cylinder Head

    30/ASSEMBLING THE ENGINE – Cover the engine case opening with a cloth. Thread the timing chain through the chain shaft. Mount the piston pin. Info For clarity, the following steps are illustrated using a disassembled piston. 300036-10 – Position the piston pin retainer. 400366-10 –...
  • Page 143: Installing Camshafts

    30/ASSEMBLING THE ENGINE Guideline Cylinder head screw Tightening Lubricated with sequence: engine oil Tighten diag- onally, begin- ning with the rear screw on the chain shaft. Step 1 15 Nm (11.1 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 45 Nm (33.2 lbf ft)
  • Page 144: Checking Valve Clearance

    30/ASSEMBLING THE ENGINE – Remove screw and use the special tool to push the timing chain tensioner  toward the timing chain. Release device for timing chain tensioner (77329051000) ( p. 216) The timing chain tensioner unlocks. – Mount and tighten screw ...
  • Page 145: Installing Spark Plug

    30/ASSEMBLING THE ENGINE – Remove shims and set them down according to the installation position.  – Correct the shims as indicated by the results of the valve clearance check. – Insert suitable shims. – Position the rocker arms and push in the rocker arm shafts. Info Make sure that the tapped hole of the rocker arm shaft is positioned facing outwards.
  • Page 146: Mounting Water Pump Cover

    30/ASSEMBLING THE ENGINE Mounting water pump cover 19.26 – Push on the shaped washer  300014-11 – Attach the water pump wheel . Mount and tighten screw   Guideline Screw, water pump wheel 10 Nm Loctite ® 243™ (7.4 lbf ft) Loctite ®...
  • Page 147: Installing Gear Position Sensor

    30/ASSEMBLING THE ENGINE – Insert the oil filter  – Lubricate the O-ring of the oil filter cover. Install the oil filter cover  – Mount and tighten the screws. Guideline Screw, oil filter cover 6 Nm (4.4 lbf ft) 300011-11 Installing gear position sensor 19.29...
  • Page 148: Installing Oil Screens

    30/ASSEMBLING THE ENGINE Installing oil screens 19.31 – Push the oil screen with O-rings on to a pin wrench. Push the pin wrench through the opening into the drill hole of the opposite engine case wall and push the oil screen as far as possible into the engine case.
  • Page 149: Installing Starter Motor

    30/ASSEMBLING THE ENGINE – Remove special tool  Engine blocking screw (77329010000) ( p. 216) – Mount and tighten screw  Guideline Plug, crankshaft location 20 Nm (14.8 lbf ft) 300024-11 Installing starter motor 19.33 – Grease O-ring. Mount the starter motor. Long-life grease ( p.
  • Page 150: 32/clutch

    32/CLUTCH Checking/rectifying the fluid level of the hydraulic clutch 20.1 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. –...
  • Page 151: 35/water Pump, Cooling System

    35/WATER PUMP, COOLING SYSTEM Draining coolant 21.1 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: Checking The Antifreeze And Coolant Level

    35/WATER PUMP, COOLING SYSTEM – Start the engine and run it until the 5th bar of the temperature indicator lights up. – Switch off the engine and allow it to cool down. – After the engine has cooled down, check the coolant level in the radiator and in the compensating tank again and add more coolant if necessary.
  • Page 153: Checking The Coolant Level

    35/WATER PUMP, COOLING SYSTEM Checking the coolant level 21.4 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 154: 38/lubrication System

    38/LUBRICATION SYSTEM Oil circuit 22.1 400500-60 Oil screen Force pump Oil filter Oil pressure regulator valve Timing chain tensioner Rocker arm shaft Transmission Clutch Oil jet for piston cooling Oil filter Crankshaft Oil screen Suction pump Transmission Checking the engine oil level 22.2 Info The engine oil level must be checked when the engine is warm.
  • Page 155: Checking The Engine Oil Pressure

    38/LUBRICATION SYSTEM – 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: –...
  • Page 156: Changing The Engine Oil And Filter, Cleaning The Oil Screens

    38/LUBRICATION SYSTEM – Change the oil filter. Check the 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.
  • Page 157: Removing The Oil Filter

    38/LUBRICATION SYSTEM – Thoroughly clean the oil drain plug with a magnet. – Check parts for damage and wear. Replace damaged or worn parts. – Refit the oil drain plug with the magnet and seal ring and tighten it. Guideline Oil drain plug with magnet M12x1.5 20 Nm...
  • Page 158: Cleaning The Oil Screens

    38/LUBRICATION SYSTEM Cleaning the oil screens 22.8 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 159: Filling Up With Engine Oil

    38/LUBRICATION SYSTEM Filling up with engine oil 22.9 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – Remove filler plug with O-ring from the clutch cover and add engine oil.  Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60) (00062010035) (...
  • Page 160: 39/ignition System

    39/IGNITION SYSTEM Alternator - checking the stator winding 23.1 Condition The stator is disconnected. – Reinstall the fuel tank. Stator winding, measurement I - check the resistance – Measure the resistance between the specified points. Stator, connector EN pin 1 – Stator, connector EN pin 2 Alternator ≤...
  • Page 161: Ignition Coil - Checking The Secondary Winding

    39/IGNITION SYSTEM Ignition coil - checking the secondary winding 23.3 Condition Ignition coil cylinder 1 is disconnected. Spark plug connector cylinder 1 has been removed. – Remove the fuel tank. Ignition coil cylinder 1 - check the secondary winding resistance –...
  • Page 162: 41/throttle Valve Body

    – Press "Continue". – Read the information page in the KTM diagnostics tool and use "Continue" to open the "Check the throttle position sensor circuit A position" menu. The motor drive moves the throttle valve to the basic position (completely closed).
  • Page 163: Adjusting The Basic Setting Of The Motor Drive

    Select "Adjusting the basic setting of the motor drive". – Press "Continue". – Read the information page in the KTM diagnostics tool and use "Continue" to open the "Adjusting the position of the throttle position sensor in circuit A" menu. 400786-60...
  • Page 164 41/THROTTLE VALVE BODY – Carefully close the throttle valve with your finger and hold it. – Check the voltage value. Info The "Continue" button only appears if the measured value equals the set- point value. Throttle position sensor circuit A Basic position - voltage "THAD"...
  • Page 165 41/THROTTLE VALVE BODY Loctite ® 648™ Info Tighten by hand only, do not use a tool. – Press "Continue". – Open and close the throttle grip fully ten times. The "Continue" button appears. – Press "Continue". – Check the voltage value. Info The "Continue"...
  • Page 166: Flashing The Efi Control Unit And/or The Ept Control Unit

    Fix screws with locking varnish.  – Press "Continue". – Read the information page on the KTM diagnostics tool and, using "Continue", start the "ECU Reset" menu. The control unit is reset. – Complete the procedure with "Continue". – Switch off the ignition by turning the ignition key in the position...
  • Page 167: Requesting The Enabling Code

    Select "Change VIN - New identity". 400687-60 – Press "Continue". – Read the information page on the KTM diagnostics tool and, using "Continue", start the coding process. – Overwrite the entry under "Please enter VIN:" with the new chassis number. Info For used control units, the chassis number programmed last is displayed.
  • Page 168: Coding The Efi Control Unit And/or Ept Control Unit

    – Select "Change VIN - New identity". – Press "Continue". – Read the information page on the KTM diagnostics tool and using "Continue" start the coding process. – Under "Please enter VIN:" enter the new VIN. Info For new control units, a sample VIN is displayed.
  • Page 169 41/THROTTLE VALVE BODY – Switch to the main menu. – Select "Show identification". – Compare the old VIN to the new VIN. The new VIN is shown.
  • Page 170: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 1-cylinder 4-stroke engine, water-cooled Displacement 654 cm³ (39.91 cu in) Stroke 80 mm (3.15 in) Bore 102 mm (4.02 in) Compression ratio 11.8:1 Control OHC, 4 valves controlled via rocker arm, chain drive Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust 34 mm (1.34 in)
  • Page 171: Technical Data - Tolerance, Wear Limits Of Engine

    TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE Camshafts - diameter, bearing pin ≥ 39.95 mm (≥ 1.5728 in) Next to exhaust cam ≥ 17.96 mm (≥ 0.7071 in) Next to inlet cam Valve spring Minimum length (without valve spring cap) 42.3 mm (1.665 in) Valve spring cap - thickness 2.4…...
  • Page 172 TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE Main shaft axial clearance 0.10… 0.40 mm (0.0039… 0.0157 in) ≤ 0.025 mm (≤ 0.00098 in) Transmission shaft run-out Shift shaft - play in sliding plate/shift quadrant 0.40… 0.80 mm (0.0157… 0.0315 in) Fuel pressure Under every load condition 3.3…...
  • Page 173: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Oil hole plug self-tapping 9 Nm (6.6 lbf ft) Loctite 243™ ® Screw, membrane fixation 2.5 Nm (1.84 lbf ft) Loctite 243™ – Hose clamp, intake flange 1.5 Nm (1.11 lbf ft) ® Oil jet, conrod lubrication 2 Nm (1.5 lbf ft) Loctite...
  • Page 174 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Plug, oil bore for oil radiator M10x1 15 Nm (11.1 lbf ft) – Screw, unlocking of timing chain ten- M10x1 10 Nm (7.4 lbf ft) sioner – Spark plug M12x1.25 17 Nm (12.5 lbf ft) –...
  • Page 175: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS Frame Lattice frame made of chrome molybdenum steel tubing, powder-coated WP Suspension Up Side Down 4860 ROMA Fork Shock absorber WP Suspension 4618 with Pro‑Lever deflector Suspension travel Front 275 mm (10.83 in) Rear 265 mm (10.43 in) Brake system Front Disc brake with radially screwed four-piston brake caliper, float-...
  • Page 176: Capacity - Fuel

    120/70 ZR 17 M/C 58W TL 160/60 ZR 17 M/C 69W TL Pirelli Dragon Supercorsa Pro Pirelli Dragon Supercorsa Pro Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 28.2 Total fuel tank capacity, 12 l (3.2 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p.
  • Page 177: Technical Data - Fork

    TECHNICAL DATA - FORK Fork part number 14.18.7D.12 Fork WP Suspension Up Side Down 4860 ROMA Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks Full payload 5 clicks...
  • Page 178: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 15.18.7D.12 Shock absorber WP Suspension 4618 with Pro‑Lever deflector Compression damping, high-speed Comfort 1.5 turns Standard 1 turn Sport 0.5 turn Full payload 0.5 turn Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport...
  • Page 179: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw, combination instrument EJOT 1 Nm (0.7 lbf ft) – Screw, combination instrument holder EJOT 1 Nm (0.7 lbf ft) – Screw, license plate holder, bottom EJOT 3 Nm (2.2 lbf ft) – Screw, SLS valve EJOT 2 Nm (1.5 lbf ft)
  • Page 180 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ® Screw, steering stem 20 Nm (14.8 lbf ft) Loctite 243™ – Screw, top triple clamp 17 Nm (12.5 lbf ft) – Upper fuel tank screw 20 Nm (14.8 lbf ft) ® Engine carrying screw 45 Nm (33.2 lbf ft) Loctite 243™...
  • Page 181: Cleaning/protective Treatment

    CLEANING/PROTECTIVE TREATMENT Cleaning the motorcycle 32.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 182: Protective Treatment For Winter Operation

    CLEANING/PROTECTIVE TREATMENT Protective treatment for winter operation 32.2 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. Warm water would enhance the corrosive effects of salt. –...
  • Page 183: Storage

    0… 35 °C (32… 95 °F) – The storage place should be dry and not subject to large temperature differences. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear wheel stand. ( p. 9) –...
  • Page 184: Service Schedule

    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 186: Wiring Diagram

    WIRING DIAGRAM Page 1 of 10 35.1 wh-rd rd-bu wh-rd wh-rd wh-rd EM/3 EN/3 bl-rd rd-bu bl-rd ye-rd wh-rd ye-rd 600974-01...
  • Page 187 WIRING DIAGRAM EFI control unit Fuse Battery Generator Starter relay with main fuse Start auxiliary relay Starter motor Voltage regulator X291 Connector for accessory ground (terminal 31) ACC 1 (not assigned) X292 Connector for accessory plus (terminal 30) ACC 1 (not assigned)
  • Page 188: 186

    WIRING DIAGRAM Page 2 of 10 35.2 ye-rd bl-rd ye-rd ye-rd ye-rd wh-rd wh-rd wh-rd wh-rd br-gr br-gr wh-rd ye-rd wh-bl wh-bl ye-rd wh-rd ye-rd ye-rd 600975-01...
  • Page 189 WIRING DIAGRAM 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...
  • Page 190: 188

    WIRING DIAGRAM Page 3 of 10 35.3 ye-bu ye-bu 600976-01...
  • Page 191 WIRING DIAGRAM Low beam, high beam Fuse Fuse Combination instrument Horn Parking light High beam/low beam switch, horn button, turn signal switch...
  • Page 192: 190

    WIRING DIAGRAM Page 4 of 10 35.4 wh-gn ye-bu wh-gn ye-bu wh-gn 600977-01...
  • Page 193 WIRING DIAGRAM Front brake light switch Brake light switch, rear License plate lamp Brake/tail light...
  • Page 194: 192

    WIRING DIAGRAM Page 5 of 10 35.5 bl-or ye-bu bl-or 600978-01...
  • Page 195 WIRING DIAGRAM 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...
  • Page 196: 194

    WIRING DIAGRAM Page 6 of 10 35.6 bl-rd bl-rd wh-bl wh-bl 600979-01...
  • Page 197 WIRING DIAGRAM Temperature switch for radiator fan Fuse Fuse Radiator fan X293 Connector for accessory ground (terminal 31) ACC 2 (not assigned) X294 Connector for accessory plus (terminal 15) ACC 2 (not assigned)
  • Page 198: 196

    WIRING DIAGRAM Page 7 of 10 35.7 br-pu br-pu br-pu br-pu ye-rd br-pu bl-bu bu-gr bu-gr bl-rd wh-br gn-or wh-bu bl-bu bl-bu ye-rd bu-or ye-rd bl-bu wh-bu gn-or wh-br bl-rd bl-rd br-pu bu-or bu-br bu-br wh-gn wh-gn wh-rd wh-rd wh-or wh-or 600980-01...
  • Page 199 WIRING DIAGRAM EFI control unit EPT control unit Fuse Fuse Fuse Fuel pump Motor drive Combination instrument X295 Diagnostics connector...
  • Page 200: 198

    WIRING DIAGRAM Page 8 of 10 35.8 bl-or bl-or rd-gr rd-gr bl-gr bl-gr wh-pu wh-pu gn-rd gn-rd wh-bu wh-bu bu-br bu-br bl-or bl-or 600981-01...
  • Page 201 WIRING DIAGRAM EFI control unit Lambda sensor (cylinder 1) Front wheel speed sensor Fuel evaporation valve (USA version only) Secondary air valve Injector (cylinder 1) Combination instrument Ignition coil (cylinder 1)
  • Page 202: 200

    WIRING DIAGRAM Page 9 of 10 35.9 ye-gn ye-gn wh-pk wh-pk ye-or ye-or ye-br ye-br bl-gn bl-gn bl-gn 600982-01...
  • Page 203 WIRING DIAGRAM EFI control unit Throttle position sensor circuit A Intake air temperature sensor Rollover sensor Side stand switch Accelerator position sensor Gear position sensor Combination instrument...
  • Page 204: 202

    WIRING DIAGRAM Page 10 of 10 35.10 gn-gr gn-gr wh-ye wh-ye ye-bu ye-bu bl-br bl-br bl-ye bl-ye bu-or bu-or br-rd br-rd 600983-01...
  • Page 205 WIRING DIAGRAM EFI control unit Ambient air pressure sensor Engine coolant temperature sensor (cylinder 1) Fuel level indicator Crankshaft position sensor Clutch switch Manifold absolute pressure sensor (cylinder 1) Combination instrument Map‑Select Switch Black Brown Blue Green Gray Light blue Orange Pink Violet...
  • Page 206: Substances

    – 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 – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 207 – 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 – Hydraulic Fluid 75...
  • Page 208: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Chain lube for road use Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Lube 622 Strong Cleaning and preserving materials for metal, rubber and plastic Guideline –...
  • Page 209 AUXILIARY SUBSTANCES Lubricant (T152) Guideline – ® KTM recommends Bel‑Ray products. Supplier ® Bel‑Ray – ® Molylube Anti‑Seize Lubricant (T159) Guideline – ® KTM recommends Bel‑Ray products. Supplier ® Bel‑Ray – ® MC‑11 Lubricant (T625) Guideline – ® KTM recommends Molykote products.
  • Page 210: Special Tools

    SPECIAL TOOLS Bearing puller Art. no.: 15112017000 400037-01 Insert for bearing puller Art. no.: 15112018100 Feature 18… 23 mm (0.71… 0.91 in) 400125-01 Bleed syringe Art. no.: 50329050000 400058-01 Circlip pliers reverse Art. no.: 51012011000 400059-01 Extractor Art. no.: 58429009000 400073-01...
  • Page 211 SPECIAL TOOLS Tool for inner bearing race Art. no.: 58429037043 400082-01 Mounting sleeve Art. no.: 58529005000 400095-01 Valve spring compressor Art. no.: 59029019000 400101-01 Limit plug gauge Art. no.: 59029026006 400104-01 Extractor Art. no.: 59029033000 400105-01...
  • Page 212 SPECIAL TOOLS Feeler gauge Art. no.: 59029041100 400110-01 Hose clamp pliers Art. no.: 60029057000 400142-01 Pliers for spring-loaded band-type clamp Art. no.: 60029057100 400085-01 Rear wheel stand Art. no.: 61029055100 500077-01 Adapter Art. no.: 61029055110 500079-01...
  • Page 213 SPECIAL TOOLS Front wheel stand Art. no.: 61029055300 500078-01 Testing hose Art. no.: 61029093000 201314-01 Pressure testing tool Art. no.: 61029094000 400149-01 Engine work stand Art. no.: 61229001000 200306-01 Work stand Art. no.: 62529055000 400151-01...
  • Page 214 SPECIAL TOOLS Support for engine work stand Art. no.: 75012001060 400153-01 Holder for engine work stand Art. no.: 75012001070 400154-01 Piston assembly ring Art. no.: 75029015102 400156-01 Extractor Art. no.: 75029021000 400157-01 Assembly screws Art. no.: 75029033000 400158-01...
  • Page 215 SPECIAL TOOLS Piston pin lock ring insert Art. no.: 75029035000 400160-01 Work stand adapter Art. no.: 75029036000 400161-01 Push-in drift Art. no.: 75029044010 500163-01 Push-in drift Art. no.: 75029044020 500162-01 Pressing device for crankshaft, complete Art. no.: 75029047000 400185-01...
  • Page 216 SPECIAL TOOLS Upper part, pressing-out tool Art. no.: 75029047050 400186-01 Under part, pressing-out tool Art. no.: 75029047051 400187-01 Extractor Art. no.: 75029048000 400162-01 Clamping plate Art. no.: 75029050000 400163-01 Push-out drift Art. no.: 75029051000 400164-01...
  • Page 217 SPECIAL TOOLS Floor jack attachment Art. no.: 75029055000 400184-01 Mounting sleeve Art. no.: 75029080000 400165-01 Gear segment Art. no.: 75029081000 400068-01 Protection cover Art. no.: 75029090000 400167-01 Holding spanner Art. no.: 75029091000 400168-01...
  • Page 218 SPECIAL TOOLS Spark plug wrench Art. no.: 75029172000 400170-01 Oil pressure adapter Art. no.: 77329006000 400176-01 Engine blocking screw Art. no.: 77329010000 400177-01 Release device for timing chain tensioner Art. no.: 77329051000 400181-01 Valve spring mounting device Art. no.: 78029060000 500165-01...
  • Page 219 SPECIAL TOOLS Spring compressor Art. no.: T101S 300573-10 Hook wrench Art. no.: T106S 301085-01 Art. no.: T120 201235-10 Pressing tool Art. no.: T1206 200583-10 Pressing tool Art. no.: T1207S 200585-01...
  • Page 220 SPECIAL TOOLS Vacuum pump Art. no.: T1240S 200273-10 Pressing tool Art. no.: T129 200584-01 Protecting sleeve Art. no.: T1401 200635-10 Gripping tool Art. no.: T14026S1 200639-10 Assembly tool Art. no.: T1402S 200634-10...
  • Page 221 SPECIAL TOOLS Open-end wrench Art. no.: T14032 200640-10 Clamping stand Art. no.: T1403S 200637-10 Mounting sleeve Art. no.: T1515 300569-10 Filling adapter Art. no.: T1516 300567-10 Hook wrench Art. no.: T157S 200899-10...
  • Page 222: 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 specifi- cation.
  • Page 223: Index

    INDEX front brake, changing ......75 INDEX rear brake, adding ......79 Accessories .
  • Page 224 INDEX primary gear, removing ..... . 102 shift shaft, preassembling ....124 rotor, removing .
  • Page 225 INDEX Fuel filter checking ....... . . 27 changing ....... . . 56 Protective treatment for winter operation .
  • Page 226 INDEX Steering head bearing play adjusting ....... . . 26 checking .
  • Page 227 *3206042en* 3206042en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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