KTM 2013 690 SMC R EU Repair Manual
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KTM 2013 690 SMC R EU Repair Manual

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REPAIR MANUAL
2013
690 SMC R EU
690 SMC R AUS/UK
Art. no. 3206153en

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  • Page 1 REPAIR MANUAL 2013 690 SMC R EU 690 SMC R AUS/UK Art. no. 3206153en...
  • 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

    TABLE OF CONTENTS Adjusting the rebound damping of the shock TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 absorber............33 Symbols used ........... 5 Measuring the unloaded rear wheel sag ..... 33 Formats used............ 5 Checking the static sag of the shock absorber ..33 SAFETY ADVICE............
  • Page 5 TABLE OF CONTENTS 12.7.8 Checking the chain, rear sprocket, engine 16.3.11 Removing water pump wheel...... 110 sprocket, and chain guide......75 16.3.12 Removing clutch cover ......110 12.7.9 Cleaning the chain ........77 16.3.13 Removing spacer and spring ...... 110 12.7.10 Checking the rear hub rubber dampers..
  • Page 6 TABLE OF CONTENTS 16.4.32 Checking shift mechanism......137 19.3 Checking the engine oil pressure ....166 16.4.33 Preassembling shift shaft ......137 19.4 Changing the engine oil and filter, cleaning the oil screens ..........167 16.4.34 Disassembling the main shaft ....138 19.5 Draining the engine oil ........

  • Page 7: Means Of Representation

    MEANS OF REPRESENTATION Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips.

  • Page 8: Safety Advice

    Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle. This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available. Safety advice A number of safety instructions need to be followed to operate the vehicle safely.

  • Page 9: 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 & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 10: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. 601858-10 Type label The type label is located on the right side of the frame. B01289-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.

  • Page 11: Shock Absorber Part Number

    SERIAL NUMBERS Shock absorber part number The shock absorber part number is on the left of the shock absorber. 601862-10...

  • Page 12: 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 13: Taking The Motorcycle Off Of The Front Wheel Stand

    MOTORCYCLE Taking the motorcycle off of the front 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. – Secure the motorcycle against falling over. –...

  • Page 14: Removing The Motorcycle From The Work Stand

    MOTORCYCLE – Position the motorcycle upright, align the special tool and raise the motorcycle. Work stand (62529055000) ( p. 214) 300201-10 Removing the motorcycle from the work stand Note Danger of damage The parked vehicle may roll away or fall over. –...

  • Page 15: Starting The Motorcycle To Make Checks

    MOTORCYCLE – Turn the emergency OFF switch to the position – Switch on the ignition by turning the ignition key to position ON After you switch on the ignition, you can hear the fuel pump working for about two seconds. The function check of the combination instrument is run at the same time.

  • Page 16: Fork, Triple Clamp

    FORK, TRIPLE CLAMP Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn adjusting screws clockwise all the way. Info The adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs.

  • Page 17: Cleaning The Dust Boots Of The Fork Legs

    FORK, TRIPLE CLAMP Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 11) – Remove the fork protector. ( p. 15) Main work – Push dust boots on both fork legs downward. Info The dust boots remove dust and coarse dirt particles from the inside fork tubes.

  • Page 18: Removing Fork Legs

    FORK, TRIPLE CLAMP Removing fork legs Preparatory work – Raise the motorcycle with the work stand. ( p. 11) – Tie the rear of the vehicle down. Main work – Remove screws and spacers – Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc.

  • Page 19: Installing The Fork Legs

    FORK, TRIPLE CLAMP – Loosen the screws of the triple clamp. Remove the fork legs from the bottom. S00058-10 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 20: Servicing The Fork

    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 21: Disassembling The Fork Legs

    FORK, TRIPLE CLAMP – Disassemble the fork legs. ( p. 19) – Check the fork legs. ( p. 22) – Assemble the fork legs. ( p. 23) 201240-01 6.10 Disassembling the fork legs Info These operations are the same on both fork legs. Condition The fork legs have been removed.
  • Page 22 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 23 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 24: Checking The Fork Legs

    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 25: Assembling The Fork Legs

    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 26 FORK, TRIPLE CLAMP – Push on lock ring – Grease and slide on seal ring Lubricant (T511) ( p. 208) Info Sealing ring downward, open side upward. – Push on support ring – Remove the special tool. – Sand the edges of the sliding bushings with 600-grain sandpaper, then clean and grease them.
  • Page 27 FORK, TRIPLE CLAMP – Mount dust boot 200655-11 – Grease the O-ring of valve of the rebound damping. Lubricant (T158) ( p. 208) – Mount valve of the rebound damping with the spring on adjusting tube – Mount valve of the rebound damping from below in cartridge The adjusting tube protrudes 5 mm from the cartridge and can be pressed in against the resistance of the spring.
  • Page 28 FORK, TRIPLE CLAMP – Clamp the fork vertically. – Fill it with fork oil. Fork oil per fork 644 ml Fork oil (SAE 4) (48601166S1) (21.77 fl. oz.) p. 207) Info Pull out the piston rod and push back in a number of times to bleed the car- tridge.

  • Page 29: Checking The Steering Head Bearing Play

    FORK, TRIPLE CLAMP – Push the outer tube upward. – Clamp the fork leg in the area of the lower triple clamp. Clamping stand (T1403S) ( p. 221) – Grease the O-ring of the screw cover. Lubricant (T511) ( p. 208) –...

  • Page 30: Adjusting The Steering Head Bearing Play

    FORK, TRIPLE CLAMP Main work – 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 31: Handlebar, Controls

    HANDLEBAR, CONTROLS Handlebar position In the upper triple clamp, there are 2 drill holes separated by a distance of Hole distance 15 mm (0.59 in) The drill holes on the handlebar holder are centered and separated by a distance of Hole distance 3.5 mm (0.138 in) The handlebar can be mounted in 4 different positions.

  • Page 32: Checking The Play In The Throttle Cable

    Main work – 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 33 HANDLEBAR, CONTROLS – Tighten counter nut...

  • Page 34: Shock Absorber, Swingarm

    SHOCK ABSORBER, SWINGARM Adjusting the high-speed compression damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. Info The high-speed setting takes effect during the fast compression of the shock absorber. –...

  • Page 35: Adjusting The Rebound Damping Of The Shock Absorber

    SHOCK ABSORBER, SWINGARM Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. – Turn adjusting screw clockwise up to the last perceptible click.

  • Page 36: Checking The Riding Sag Of The Shock Absorber

    SHOCK ABSORBER, SWINGARM Checking the riding sag of the shock absorber – Measure distance of rear wheel unloaded. ( p. 33) – 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 37: Adjusting The Riding Sag

    SHOCK ABSORBER, SWINGARM Adjusting the riding sag Preparatory work – Raise the motorcycle with the work stand. ( p. 11) – Remove the seat. ( p. 59) – Take off the side cover. ( p. 60) – Remove the shock absorber. ( p.

  • Page 38: Installing The Shock Absorber

    SHOCK ABSORBER, SWINGARM – Lift the rear fairing. – Remove screws S00064-12 – Remove screws S00065-10 – Loosen screw – Remove screw – Remove screw S00066-10 – Fold the rear upward. – Take out shock absorber toward the top. S00067-10 8.10 Installing the shock absorber Main work...
  • Page 39 SHOCK ABSORBER, SWINGARM – Mount screw but do not tighten yet. – Mount and tighten screw Guideline Screw, bottom shock 45 Nm Loctite ® 243™ absorber (33.2 lbf ft) – Tighten screw Guideline Screw, top shock absorber 45 Nm Loctite ®...

  • Page 40: Servicing The Shock Absorber

    SHOCK ABSORBER, SWINGARM – Mount the seat. ( p. 60) – Remove the motorcycle from the work stand. ( p. 12) 8.11 Servicing 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. Condition The shock absorber has been removed.

  • Page 41: Dismantling The Damper

    SHOCK ABSORBER, SWINGARM 8.13 Dismantling the damper Preparatory work – Remove the spring. ( p. 38) Main work – Establish and note the current state of the rebound damping and compression damping. – Completely open the adjusters of the rebound and compression damping. –...

  • Page 42: Disassembling The Piston Rod

    SHOCK ABSORBER, SWINGARM – Remove compression adjuster . Remove the spring, sleeve, and piston. 201279-10 8.14 Disassembling the piston rod Preparatory work – Remove the spring. ( p. 38) – Dismantle the damper. ( p. 39) Main work – Clamp the piston rod with the heim joint in a vise. –...

  • Page 43: Checking The Damper

    SHOCK ABSORBER, SWINGARM – Remove seal ring retainer 300542-10 – Remove locking cap and rubber buffer 300543-10 8.15 Checking the damper Condition The damper has been disassembled. – Measure the inside diameter at both ends and in the center of the damper car- tridge.

  • Page 44: Removing The Heim Joint

    SHOCK ABSORBER, SWINGARM – Check the heim joint for damage and wear. » If there is damage or wear: – Change the heim joint. 300460-01 8.16 Removing the heim joint Condition The shock absorber has been removed. – Clamp the shock absorber in the vise using soft jaws for protection. –...

  • Page 45: Installing The Heim Joint

    SHOCK ABSORBER, SWINGARM – Place special tool underneath and press out the heim joint with special tool Pressing tool (T1207S) ( p. 220) 200580-10 8.17 Installing the heim joint – Place special tool underneath and press in the heim joint as far as the center using special tool Pressing tool (T1206) ( p.

  • Page 46: Assembling The Piston Rod

    SHOCK ABSORBER, SWINGARM 8.18 Assembling the piston rod Preparatory work – Check the damper. ( p. 41) Main work – Clamp the piston rod with the heim joint in a vise. Guideline Use soft jaws. – Mount rubber buffer and locking cap 300543-11 –...

  • Page 47: Assembling The Damper

    SHOCK ABSORBER, SWINGARM – Mount and tighten nut Guideline Piston rod nut M12x1 40 Nm (29.5 lbf ft) 300540-11 8.19 Assembling the damper Preparatory work – Check the damper. ( p. 41) – Assemble the piston rod. ( p. 44) Main work –...
  • Page 48 SHOCK ABSORBER, SWINGARM – Grease O-ring of the seal ring retainer. Lubricant (T158) ( p. 208) – Mount the piston rod carefully. 201278-11 – Install the seal ring bearer and push it under the ring groove. – Mount lock ring Info Do not scratch the inner surface.

  • Page 49: Bleeding And Filling The Damper

    SHOCK ABSORBER, SWINGARM Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seri- ously alter the vehicle's ride behavior. – Extreme modifications to the adjustment of the suspension compo- nents can cause a serious deterioration in the handling characteris- tics and overload some components.
  • Page 50 SHOCK ABSORBER, SWINGARM – Measure distance between the floating piston and reservoir hole with the special tool. Depth micrometer (T107S) ( p. 219) The floating piston is positioned all the way at the bottom. 201285-10 – When the vacuum pressure gauge reaches the specified value, turn the Oil reser- voir control lever to Equalize pressure.

  • Page 51: Filling The Damper With Nitrogen

    SHOCK ABSORBER, SWINGARM – When the pressure gauge reaches the specified value, turn the Damper control lever to Pressure. Guideline 0 bar Oil is pumped into the damper. The pressure gauge rises to the specified value. 3 bar 200268-10 – When the pressure gauge reaches the specified value, turn the Damper control lever to Vacuum.

  • Page 52: Installing The Spring

    SHOCK ABSORBER, SWINGARM – Clamp special tool in the vise. Nitrogen filling tool (T170S1) ( p. 222) – Connect the special tool to the pressure regulator of the filling cylinder. Filling gas - nitrogen – Adjust pressure regulator. Guideline Gas pressure 10 bar (145 psi) 201281-10 –...
  • Page 53 SHOCK ABSORBER, SWINGARM Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seri- ously alter the vehicle's ride behavior. – Extreme modifications to the adjustment of the suspension compo- nents can cause a serious deterioration in the handling characteris- tics and overload some components.

  • Page 54: Exhaust

    EXHAUST Removing the manifold Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. Preparatory work – Remove the seat. ( p. 59) –...

  • Page 55: Removing The Main Silencer

    EXHAUST – Position the screw clamp. – Tighten screw Guideline Screw, main silencer 12 Nm Copper paste clamp (8.9 lbf ft) S00070-10 – Plug in connector of the lambda sensor. Position the cable and secure it with cable binders 202035-10 –...

  • Page 56: Installing The Main Silencer

    EXHAUST – Loosen screw S00071-10 – Remove screws – Remove grab handle S00062-12 – Remove screws – Lift the rear fairing. S00072-10 – Remove screws – Remove the main silencer. S00073-11 Installing the main silencer Main work – Position the main silencer. –...
  • Page 57 EXHAUST – Position the exhaust heat guard. – Mount and tighten screws Guideline Screw, exhaust heat shield 8 Nm Loctite ® 243™ (5.9 lbf ft) S00061-13 – Mount and tighten screws Guideline Rear fairing screw 5 Nm (3.7 lbf ft) S00072-11 –...

  • Page 58: Air Filter

    AIR FILTER 10.1 Removing the air filter Preparatory work – Remove the seat. ( p. 59) Main work – Remove screws . Take off air filter box top 601882-10 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine.

  • Page 59: Installing The Air Filter Box

    AIR FILTER Main work – Remove screws – Take off the voltage regulator and hang it to the side in a de-energized state. – Detach and expose hose S00074-10 – Remove screws S00075-10 – Remove screws S00076-10 – Loosen hose clip S00077-10 –...
  • Page 60 AIR FILTER – Position the air filter box. – Mount and tighten hose clip S00077-11 – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) S00076-10 – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) S00075-11 –...

  • Page 61: Fuel Tank, Seat, Trim

    FUEL TANK, SEAT, TRIM 11.1 Opening the filler cap Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 62: Mounting The Seat

    FUEL TANK, SEAT, TRIM 11.4 Mounting the seat 601887-10 – Hook slot of the seat onto screw , press the rear downward and at the same time push it forward. – Push locking pin into lock housing and push the back of the seat down until the locking pin locks in place with an audible click.

  • Page 63: Changing The Fuel Filter

    FUEL TANK, SEAT, TRIM Ensure that the battery voltage does not drop below 12.5 V. The ignition is on. The diagnostics tool is connected. – Press on the metal plate and disconnect the fuel hose connection Info Remaining fuel may run out of the fuel hose. 302037-10 –...
  • Page 64 FUEL TANK, SEAT, TRIM Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water.
  • Page 65 FUEL TANK, SEAT, TRIM – Remove screws – Pull out the fuel pump. S00113-10 – Disconnect both fuel hose connections – Unplug connector . Remove the fuel pump. S00328-10 – Remove hose clamps – Remove fuel filter. – Mount the new fuel filter. Arrow points away from the fuel pump.
  • Page 66 FUEL TANK, SEAT, TRIM – Position the fuel pump. – Mount and tighten screws Guideline Screw, fuel pump 4 Nm (3 lbf ft) S00113-10 – Position the splash protector. Mount and tighten screws Guideline Remaining screws, chassis 4 Nm (3 lbf ft) S00327-10 –...

  • Page 67: Changing The Fuel Pump

    FUEL TANK, SEAT, TRIM 11.9 Changing the fuel pump 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 68 FUEL TANK, SEAT, TRIM – Remove screws and the splash protector. S00327-10 – Remove screws – Pull out the fuel pump. S00113-10 – Disconnect both fuel hose connections – Unplug connector . Remove the fuel pump. – Connect the new fuel pump, attaching both fuel hose connections –...
  • Page 69 FUEL TANK, SEAT, TRIM – Lift the rear fairing. – Mount and tighten screws Guideline Screw, main silencer holder on fuel 25 Nm tank (18.4 lbf ft) S00064-10 – Mount and tighten screws Guideline Screw, side cover 5 Nm (3.7 lbf ft) S00063-10 Finishing work –...

  • Page 70: Wheels

    The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning Danger of accidents Uncontrollable handling 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 71: 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 5 years. »...

  • Page 72: Checking The Rim Run-Out

    WHEELS 12.5 Checking the rim run-out Warning Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time. If the spokes are too tight, they can break due to local overload.

  • Page 73: Installing The Front Wheel

    WHEELS – Remove distance bushings S00083-11 12.6.2 Installing the front 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. Main work –...

  • Page 74: Removing The Brake Disc Of The Front Brake

    WHEELS 12.6.3 Removing the brake disc of the front brake Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 10) – Raise the motorcycle with the front wheel stand. ( p. 10) – Remove front wheel. ( p.

  • Page 75: Installing The Rear Wheel

    WHEELS 12.7.2 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 76: Installing The Brake Disc Of The Rear Brake

    WHEELS Main work – Remove screws . Take off the brake disc. S00123-10 12.7.4 Installing the brake disc of the rear brake Main work – Clean the contact surface of the brake disc. – Position the brake disc with the label facing outward. Mount and tighten screws Guideline Screw, rear brake disc 14 Nm...

  • Page 77: Adjusting The Chain Tension

    WHEELS 12.7.6 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear- ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases.
  • Page 78 WHEELS Main work – Shift the transmission to neutral. – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket and engine sprocket are worn: – Change the power set. Info The engine sprocket, rear sprocket, and chain should always be replaced together.

  • Page 79: Cleaning The Chain

    WHEELS – 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 80: Checking The Rear Hub Rubber Dampers

    WHEELS – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( p. 208) – After drying, apply chain spray. Chain lube for road use ( p.

  • Page 81: Wiring Harness, Battery

    WIRING HARNESS, BATTERY 13.1 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 82: Connecting The Battery

    – Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 83: Checking The Charging Voltage

    WIRING HARNESS, BATTERY Main work – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the bat- tery.

  • Page 84: Changing The Main Fuse

    WIRING HARNESS, BATTERY 13.7 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers in the vehicle. It is in the housing of the starter relay next to the battery. Preparatory work –...

  • Page 85: Adjusting The Engine Characteristic

    WIRING HARNESS, BATTERY – Remove the defective fuse. Guideline Fuse 1 - 10 A - ignition, combination instrument Fuse 2 - 10 A - clock, ignition (EFI control unit) Fuse 3 - 10 A - EPT control unit Fuse 4 - 10 A - fuel pump Fuse 5 - 10 A - radiator fan Fuse 6 - 10 A - horn, brake light, turn signal Fuse 7 - 15 A - high beam, low beam, parking light, tail light, license plate lamp...
  • Page 86 WIRING HARNESS, BATTERY – Turn the adjusting wheel until the desired digit is next to marking Set the Map‑Select switch to Soft. – Set the adjusting wheel to position 1. Soft – reduced homologated peak performance for better driveability. Set the Map‑Select switch to Advanced. –...

  • Page 87: 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 88: Adjusting The Basic Position Of The Hand Brake Lever

    BRAKE SYSTEM – 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 89: Adding Front Brake Fluid

    BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Check the brake fluid level in the viewer » When the brake fluid level drops below the MIN mark: – Add front brake fluid. ( p.

  • Page 90: Changing The Front Brake Fluid

    BRAKE SYSTEM 14.6 Changing the front brake fluid Warning Skin irritation Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles. –...

  • Page 91: Checking The Rear Brake Linings

    BRAKE SYSTEM Info This prevents overfilling of the brake fluid reservoir. – Tighten the bleeder screw. Remove the hose of the bleeder bottle. Mount the pro- tection cap. – Disconnect the bleeding device. Remove the bleeder cover. – Correct the brake fluid level. Guideline Add brake fluid to level 5 mm (0.2 in)
  • Page 92 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 93: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 14.9 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 overheating.

  • Page 94: Adding Rear Brake Fluid

    BRAKE SYSTEM – Stand the vehicle upright. – Check the brake fluid level in the brake fluid reservoir. » If the fluid level reaches the MIN marking – Add rear brake fluid. ( p. 92) 601898-10 14.12 Adding rear brake fluid Warning Danger of accidents Failure of the brake system.

  • Page 95: Changing The Rear Brake Fluid

    BRAKE SYSTEM 14.13 Changing the rear brake fluid Warning Skin irritation Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles. –...
  • Page 96 BRAKE SYSTEM Info This prevents overfilling of the brake fluid reservoir. – Tighten the bleeder screw. Remove the hose of the bleeder bottle. Mount the pro- tection cap. – Disconnect the bleeding device. Remove the bleeder cover. – Add brake fluid to the MAX mark Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 97: Lighting System, Instruments

    LIGHTING SYSTEM, INSTRUMENTS 15.1 Combination instrument 15.1.1 Setting kilometers or miles 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 to position ON –...

  • Page 98: Setting The Wheel Circumference

    LIGHTING SYSTEM, INSTRUMENTS – Switch on the ignition by turning the ignition key to position ON – Press the MODE button repeatedly until the TRIP 2 mode is active. – Keep the SET button pressed. The TRIP 2 display is set to 0.0. 400841-01 15.1.5 Setting the wheel circumference...

  • Page 99: Checking The Headlight Setting

    LIGHTING SYSTEM, INSTRUMENTS 15.2 Checking the headlight setting – Stand the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight. – Make another mark at a distance under the first mark.

  • Page 100: Installing The Headlight Mask With The Headlight

    LIGHTING SYSTEM, INSTRUMENTS 15.5 Installing the headlight mask with the headlight Main work – Connect the connectors of headlight and turn signal lights – Check lighting function. 601910-11 – Remove the cloth from the fender and position the headlight mask. Holding lugs reach into the headlight mask.

  • Page 101: Changing The Headlight Bulb

    LIGHTING SYSTEM, INSTRUMENTS Main work – Remove protection cap 600610-12 – 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 102: Changing The Turn Signal Bulb

    LIGHTING SYSTEM, INSTRUMENTS 15.8 Changing the turn signal 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 103: Engine

    ENGINE 16.1 Removing the engine Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. ( p. 59) – Disconnect the battery. ( p. 79) – Raise the motorcycle with the work stand. ( p.
  • Page 104 ENGINE – Take off the engine sprocket. – Take off the clutch slave cylinder and hang it to the side. Info Do not kink the clutch line. Do not activate the clutch lever if the clutch slave cylinder has been removed.

  • Page 105: Installing The Engine

    ENGINE – Remove nut – Remove screws – Remove the engine bearer on the left and right. S00097-10 – Position the floor jack under the engine and fix it using the special tool. Floor jack attachment (75029055000) ( p. 217) 300222-10 –...
  • Page 106 ENGINE Main work – Position the engine in the frame. Info You should have an assistant for this step. Make sure that the motorcycle is sufficiently secured against falling over. Protect the frame and attachments from damage. – Mount swingarm pivot. –...
  • Page 107 ENGINE – Attach the spark plug connector – Plug in the connector of the engine coolant temperature sensor – Position the oil pressure sensor and mount and tighten screw – Detach connector of the oil pressure sensor. S00093-11 – Reconnect connectors of the gear position sensor, the crankshaft position sen- sor, and the alternator.
  • Page 108 ENGINE – Have an assistant operate the rear brake. – Tighten nut Guideline Nut, engine sprocket M20x1.5 80 Nm Loctite ® 243™ (59 lbf ft) – Secure the nut with lock washer. S00089-12 – Position the engine sprocket cover. – Mount and tighten screw Guideline Remaining screws, chassis...

  • Page 109: Engine Disassembly

    ENGINE – 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. 165) – Check the coolant level. ( p. 164) 16.3...

  • Page 110: Removing Valve Cover

    ENGINE 16.3.4 Removing valve cover – Remove screws . Take off the valve cover with the valve cover seal. 300003-10 16.3.5 Removing the alternator cover – Remove screws . Take off the alternator cover. – Remove dowels. 300004-10 16.3.6 Removing spacer –...

  • Page 111: Removing Oil Filter

    ENGINE 16.3.8 Removing oil filter – Remove screws. Remove the oil filter cover with the O-ring. – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) ( p. 211) 300009-10 – Remove screws. Remove the oil filter cover with the O-ring.

  • Page 112: Removing Water Pump Wheel

    ENGINE 16.3.11 Removing water pump wheel – Remove screws . Take off the water pump cover. 300012-10 – Remove screw . Take off the water pump wheel – Take off the water pump cover seal. Info Do not lose the centering pins. 300013-10 –...

  • Page 113: Removing Spark Plug

    ENGINE 16.3.14 Removing spark plug – Remove the spark plug using the special tool Spark plug wrench (75029172000) ( p. 218) 300016-10 16.3.15 Removing timing chain tensioner – Remove screw . Take off the seal ring. – Pull out timing chain tensioner 300017-10 16.3.16 Removing camshafts –...

  • Page 114: Removing Piston

    ENGINE 16.3.18 Removing piston – Take off the cylinder head gasket – Remove screw – Push the cylinder upward. Info Push the cylinder upward only far enough to allow removal of the piston pin. Ensure that the two grooved pins remain in place. 302127-10 –...

  • Page 115: Removing Timing Chain Rails

    ENGINE 16.3.20 Removing timing chain rails – Remove screws – Pull the timing chain guide rails out of the timing chain securing guide Info The support bushing is plugged through the timing chain guide rails into the timing chain securing guide. –...

  • Page 116: Removing Clutch Cage

    ENGINE 16.3.23 Removing clutch cage – Clamp the antihopping clutch with special tool Assembly screws (75029033000) ( p. 215) Info Apply the special tool with the hand only, do not use another tool. 300051-10 – Loosen the screws diagonally and remove them with their spring retainers and clutch springs.

  • Page 117: Removing Primary Gear

    ENGINE 16.3.24 Removing primary gear – Plug the special tool into the crankshaft. Protection cover (75029090000) ( p. 218) – Screw the special tool on to the primary gear Extractor (75029021000) ( p. 215) – Hold it using the special tool and pull off the primary gear by turning the screw in. –...

  • Page 118: Removing Locking Lever

    ENGINE 16.3.28 Removing locking lever – Remove screw – Take off locking lever with the sleeve and spring. 300069-10 16.3.29 Removing oil pumps – Remove the lock washers and normal washers from both oil pumps. – Take off the oil pump toothed wheels 300070-10 –...

  • Page 119: Removing Crankshaft And Balancer Shaft

    ENGINE – Install the special tool with suitable screws. Extractor (75029048000) ( p. 217) 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 120: Work On Individual Parts

    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 121 ENGINE – Warm the engine case section again. Guideline 150 °C (302 °F) – Insert the new cold bearings into the bearing seats of the hot engine case section and, if necessary, use a suitable press drift to push the bearing from the inside to the outside, all the way to the stop or so it is flush.

  • Page 122: Work On The Left Section Of The Engine Case

    ENGINE 16.4.2 Work on the left section of the engine case – Remove all dowels. – Remove oil jet – Remove the shaft seal ring of countershaft and shift shaft Info The shaft seal ring of the crankshaft cannot be removed before the crankshaft bearing.

  • Page 123: Work On The Clutch Cover

    ENGINE – Mount and tighten screw with the washer. Guideline Locking screw for bearing 6 Nm Loctite ® 243™ (4.4 lbf ft) – Press in the shaft seal ring of countershaft and shift shaft with the open side facing inwards so that it is flush. –...

  • Page 124: Removing Crankshaft Bearing Inner Ring

    ENGINE 16.4.4 Removing crankshaft bearing inner ring – Fix the crankshaft with special tools in the vise. Upper part, pressing-out tool (75029047050) ( p. 216) Under part, pressing-out tool (75029047051) ( p. 216) 302145-10 – Heat the special tool Guideline 150 °C (302 °F) Tool for inner bearing race (58429037043) ( p.
  • Page 125 ENGINE – Press the crank pin out of the crankweb. 300138-10 – Press in the new crank pin as far as possible. Info The crank pin must be pressed in so that oil channel is aligned with oil channel If the oil channels are not correctly aligned, the conrod bearing will not be supplied with oil.

  • Page 126: Checking Crankshaft Run-Out At Bearing Pin

    ENGINE – Install the crankshaft bearing inner ring. ( p. 124) – Measure the axial clearance of the crankshaft and the balancer shaft. ( p. 125) 16.4.7 Checking crankshaft run-out at bearing pin – Position the crankshaft on a roller block. –...

  • Page 127: Measuring Axial Clearance Of Crankshaft And Balancer Shaft

    ENGINE – Repeat the operation on the opposite side. – Make sure that the new inner bearing race is installed flush. Info After changing the crankshaft bearing and the conrod bearing, measure the axial play of the crankshaft. Finishing work –...

  • Page 128: Checking/Measuring The Cylinder

    ENGINE 16.4.12 Checking/measuring the cylinder – 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. » If the cylinder bearing surface is damaged: –...

  • Page 129: Checking Piston Ring End Gap

    ENGINE – 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. – Check the piston pin for discoloration or signs of wear. »...

  • Page 130: Checking Oil Pumps For Wear

    ENGINE 16.4.16 Checking oil pumps for wear Info The oil pump wear check shown here is on the suction pump but it applies to all oil pumps. – Use a feeler gauge to measure the play between the external rotor and the engine case as well as between the external rotor and the internal rotor.

  • Page 131: Preparing Timing Chain Tensioner For Installation

    ENGINE – Mount the autodecompression shaft in the camshaft. Install a new lock ring. – Check the functioning. » If the autodecompression spring does not completely retract the autodecom- pression shaft: – Replace the autodecompression spring. 16.4.18 Preparing timing chain tensioner for installation –...

  • Page 132: Removing Rocker Arm

    ENGINE 16.4.20 Removing rocker arm – Remove screws 300113-10 – Screw a suitable screw into the rocker arm shafts . Pull out the rocker arm shafts. – Take off the rocker arm 300114-10 16.4.21 Changing camshaft bearing Preparatory work – Remove the rocker arm.

  • Page 133: Removing Valves

    ENGINE – Press in the large camshaft bearing as far as possible using the special tool Push-in drift (75029044010) ( p. 216) 300230-10 Finishing work – Install the rocker arm. ( p. 134) 16.4.22 Removing valves – Take shims out of the valve spring retainers and lay them to one side according to their normal built-in position.

  • Page 134: Checking Valve Springs

    ENGINE – Check the sealing seat on the valve. Valve - sealing seat width Intake 1.60 mm (0.063 in) 0 0 A Valve - sealing seat width Exhaust 2.00 mm (0.0787 in) » If the sealing area is not in the center of the valve seat or deviates from the specified value: 400373-10 –...

  • Page 135: Installing Valves

    ENGINE – Check sealing seat of the valves. Valve - sealing seat width Intake 1.60 mm (0.063 in) 0 0 A Valve - sealing seat width Exhaust 2.00 mm (0.0787 in) » If the measured value does not equal the specified value: –...

  • Page 136: Installing Rocker Arm

    ENGINE 16.4.28 Installing rocker arm – 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. 300114-11 –...
  • Page 137 ENGINE 0 0 bk 0 0 4 0 0 5 0 0 6 0 0 2 0 0 9 0 0 b l 0 0 1 0 0 b o 0 0 3 0 0 b n 0 0 b m 0 0 7 0 0 8 300123-01...

  • Page 138: Preassembling The Antihopping Clutch

    ENGINE – Check clutch facing discs for discoloration and scoring. » If there is discoloration or scoring: – Change all clutch facing discs. – Check the thickness of clutch facing discs ≥ 2.5 mm (≥ 0.098 in) Clutch facing disc - thickness »...

  • Page 139: Checking Shift Mechanism

    ENGINE 16.4.32 Checking shift mechanism – Check the shift forks (see ) for damage and wear (visual check). 0 0 A » If there is damage or wear: – 0 0 1 Change the shift fork and gear wheel pair. 0 0 4 0 0 1 –...

  • Page 140: Disassembling The Main Shaft

    ENGINE 16.4.34 Disassembling the main shaft 301980-01 – Fix the main shaft in the vise with the geared end facing downward. Guideline Use soft jaws. – Remove stop disk and second-gear fixed gear – Remove the sixth-gear idler gear – Remove the split needle bearing and stop disk –...

  • Page 141: Checking The Transmission

    ENGINE – Remove stop disk and first-gear idler gear – Remove needle bearing and stop disk – Remove fifth-gear sliding gear and lock ring – Remove stop disk and third-gear idler gear – Remove needle bearing and the fourth-gear idler gear –...

  • Page 142: Assembling The Main Shaft

    ENGINE » If the sliding gear does not move easily: – Change the sliding gear or the main shaft. – Check sliding gears for smooth operation in the profile of countershaft » If the fixed gear does not move easily: –...

  • Page 143: Assembling Countershaft

    ENGINE 16.4.38 Assembling countershaft Info Use new lock rings in every repair job. Preparatory work – Oil all parts carefully before assembling. – Check the transmission. ( p. 139) Main work 300128-02 – Fix the countershaft in the vise with the geared end facing downward. Guideline Use soft jaws –...

  • Page 144: Checking The Starter Drive

    ENGINE 16.4.39 Checking the starter drive 300129-01 – Check the teeth and seating of the starter idler gear for damage and wear. » If there is damage or wear: – Replace the starter idler gear and/or needle bushing. – Check the teeth and seating of the torque limiter for damage and wear.

  • Page 145: Removing Freewheel

    ENGINE 16.4.41 Removing freewheel – Extract the lock ring from the groove using suitable pliers. 300127-10 – Compress the expansion ring and remove it, using suitable pliers. – Take the freewheel out of the primary gear. 300128-10 16.4.42 Installing freewheel –...

  • Page 146: Engine Assembly

    ENGINE – Insert the lock ring into the groove with suitable pliers and check that it is seated correctly. 300127-11 16.5 Engine assembly 16.5.1 Installing transmission shafts – Clamp the right section of the engine case. Holder for engine assembly stand (75012001070) ( p.

  • Page 147: Installing Crankshaft And Balancer Shaft

    ENGINE – Install the shift rail – Check the transmission for smooth operation. 300079-11 – Install the shim and lock ring of the countershaft. 300082-11 16.5.2 Installing crankshaft and balancer shaft – Mount the special tool on the alternator side of the crankshaft. Mounting sleeve (75029080000) ( p.

  • Page 148: Installing Left Engine Case

    ENGINE 16.5.3 Installing left engine case – Mount the dowels. – Mount the O-ring – Degrease the sealing area. Apply the sealing compound to the left engine case half. Loctite ® 5910 302132-11 – Put on the left engine case half. If necessary, tap lightly with a rubber mallet and turn the transmission shafts.

  • Page 149: Installing Locking Lever

    ENGINE 16.5.5 Installing locking lever – Position locking lever with sleeve and spring – Mount and tighten screw Guideline Screw, locking lever 10 Nm Loctite ® 243™ (7.4 lbf ft) 300069-11 16.5.6 Installing shift drum locating – Press locking lever down and position shift drum locating.

  • Page 150: Installing Primary Gear

    ENGINE – Push on the starter idler gear with washer. Mount lock ring. – Push on the needle bearing and torque limiter with washer. Mount lock ring. 300064-11 16.5.9 Installing primary gear – Ensure that the spring washer is seated properly. –...

  • Page 151: Installing Crankshaft Position Sensor

    ENGINE – Position a new lock washer and install the nut – Lock the clutch basket and primary gear using special tool and tighten the nut. Guideline Nut, inner clutch hub M20x1.5 100 Nm Loctite ® 243™ (73.8 lbf ft) Gear segment (75029081000) ( p.

  • Page 152: Installing Timing Chain And Timing Chain Sprocket

    ENGINE 16.5.12 Installing timing chain and timing chain sprocket – Heat the timing chain sprocket and push it immediately on to the crankshaft. Guideline 100 °C (212 °F) – Mount lock ring 300150-10 – Thread the timing chain in and lay it over the timing chain sprocket. Info If the timing chain is not new, pay attention to the direction of travel.

  • Page 153: Adjusting Crankshaft Position Sensor Distance

    ENGINE – Mount the tab washer and the nut . Tighten nut. Guideline Rotor nut M18x1.5 100 Nm (73.8 lbf ft) 300043-10 16.5.15 Adjusting crankshaft position sensor distance – Adjust the distance between the crankshaft position sensor and the conductive element of the rotor using the special tool Guideline Crankshaft position sensor/rotor -...
  • Page 154 ENGINE – Ensure that piston marking faces the outfeed side. 302599-10 – Apply a thin layer of sealing compound in area Loctite ® 5910 – Place the cylinder base gasket on. Info Make sure the grooved pins are seated correctly. 302598-10 –...

  • Page 155: Installing Cylinder Head

    ENGINE – Remove the cloth. – Keep the timing chain tensioned. Push the cylinder down carefully and let the grooved pins engage. 300039-10 16.5.18 Installing cylinder head – Put on the cylinder head gasket. Info Make sure the grooved pins are seated correctly. –...

  • Page 156: Installing Timing Chain Tensioner

    ENGINE – Position the camshaft support plate . Mount and tighten screw Guideline Screw, camshaft support 10 Nm Loctite ® 243™ plate (7.4 lbf ft) 300022-10 16.5.20 Installing timing chain tensioner – Insert the timing chain tensioner – Mount and tighten plug with the new seal ring.

  • Page 157: Adjusting Valve Clearance

    ENGINE – Remove the special tool. Engine blocking screw (77329010000) ( p. 219) – Mount and tighten screw with the washer. Guideline Screw plug, crankshaft clamp 20 Nm (14.8 lbf ft) 306140-10 16.5.22 Adjusting valve clearance – Remove screws Info Make sure that the crankshaft is at top dead center.

  • Page 158: Installing Spark Plug

    ENGINE 16.5.23 Installing spark plug – Mount and tighten the spark plug using the special tool. Guideline Spark plug M12x1.25 18 Nm (13.3 lbf ft) Spark plug wrench (75029172000) ( p. 218) 300016-11 16.5.24 Installing spacer and spring – Install the spacer and spring of the shift shaft.

  • Page 159: Installing Thermostat

    ENGINE – Put on the water pump cover . Mount and tighten screws. Guideline Screw, water pump cover 10 Nm (7.4 lbf ft) 300012-12 16.5.27 Installing thermostat – Position the thermostat with the gasket. The drill hole must face upward. –...

  • Page 160: Installing The Spacer

    ENGINE – Install the gear position sensor – Position the ground wire – Mount and tighten the screws. Guideline Loctite ® 243™ Screw, gear sensor 5 Nm (3.7 lbf ft) 302126-11 16.5.30 Installing the spacer – Grease spacer in area and O-ring before mounting.

  • Page 161: Installing Alternator Cover

    ENGINE – Position the oil screen with O-rings. – Mount and tighten screw plug with the O-ring. Guideline Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) 300161-11 16.5.32 Installing alternator cover – Apply sealing compound lightly in the area of the cable sleeve. –...

  • Page 162: Installing Valve Cover

    ENGINE 16.5.34 Installing valve cover – Put the valve cover in place with the seal. Mount and tighten screws Guideline Screw, valve cover 10 Nm (7.4 lbf ft) 300003-10 16.5.35 Removing the engine from the engine assembly stand – Remove the screw or the nut –...

  • Page 163: Clutch

    CLUTCH 17.1 Checking/rectifying the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...

  • Page 164: Water Pump, Cooling System

    WATER PUMP, COOLING SYSTEM 18.1 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 165: Checking The Antifreeze And Coolant Level

    WATER PUMP, COOLING SYSTEM – Remove the cap from compensating tank and add coolant to the level shown in the figure. – Mount the cap of the compensating tank. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.

  • Page 166: Checking The Coolant Level

    WATER PUMP, COOLING SYSTEM » If the coolant level does not meet specifications: – Correct the coolant level and find out the cause of the loss. Alternative 1 Coolant ( p. 206) Alternative 2 Coolant (mixed ready to use) ( p.

  • Page 167: Lubrication System

    LUBRICATION SYSTEM 19.1 Oil circuit 400500-60 Oil circuit of force pump 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 Oil nozzle for conrod bearing lubrication Oil circuit of suction pump Oil screen Suction pump...

  • Page 168: Checking The Engine Oil Pressure

    LUBRICATION SYSTEM Main work – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level. The engine oil must be between the lower and upper edge of the oil level viewer. » If the engine oil level is not at the specified level: –...

  • Page 169: Changing The Engine Oil And Filter, Cleaning The Oil Screens

    LUBRICATION SYSTEM – Change the oil filter. Check oil pumps for wear. Check that all oil holes are clear. – Switch off the engine. Warning Danger of burns Some vehicle components get very hot when the machine is driven. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.

  • Page 170: Removing The Oil Filter

    LUBRICATION SYSTEM – Thoroughly clean the oil drain plug with a magnet. – Mount the oil drain plug with the magnet and seal ring and tighten it. Guideline Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) 100201-01 19.6 Removing the oil filter Warning...

  • Page 171: Cleaning The Oil Screens

    LUBRICATION SYSTEM 19.8 Cleaning the oil screens Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 172: Filling Up With Engine Oil

    LUBRICATION SYSTEM 19.9 Filling up with engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. Main work – Remove filler plug with O-ring from the clutch cover and add engine oil. Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60)

  • Page 173: Ignition System

    IGNITION SYSTEM 20.1 Alternator - checking the stator winding Condition The stator is disconnected. Preparatory work – Remove the seat. ( p. 59) – Take off the side cover. ( p. 60) Main work Stator winding, measurement I - check the resistance –...

  • Page 174: Ignition Coil - Checking The Secondary Winding

    IGNITION SYSTEM Ignition coil – checking the secondary winding 20.3 Condition Ignition coil cylinder 1 is disconnected. Spark plug connector cylinder 1 has been removed. Preparatory work – Remove the seat. ( p. 59) – Take off the side cover. ( p.

  • Page 175: Technical Data

    TECHNICAL DATA 21.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 690 cm³ (42.11 cu in) Stroke 84.5 mm (3.327 in) Bore 102 mm (4.02 in) Compression ratio 12.5:1 Control OHC, 4 valves controlled via rocker arm, chain drive Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust 34 mm (1.34 in)
  • Page 176 TECHNICAL DATA Exhaust 2.00 mm (0.0787 in) Valve - run-out ≤ 0.05 mm (≤ 0.002 in) On the valve plate ≤ 0.05 mm (≤ 0.002 in) On the valve stem ≤ 0.10 mm (≤ 0.0039 in) Cylinder/cylinder head - sealing area distortion Cylinder - bore diameter Size I 102.000…...

  • Page 177: Engine Tightening Torques

    TECHNICAL DATA 21.3 Engine tightening torques ® Screw, membrane fixation 2 Nm (1.5 lbf ft) Loctite 243™ – Hose clip, intake flange 2.5 Nm (1.84 lbf ft) ® Oil nozzle for conrod bearing lubrica- 2 Nm (1.5 lbf ft) Loctite 243™...

  • Page 178: Capacities

    TECHNICAL DATA ® Screw plug, oil channel M10x1 15 Nm (11.1 lbf ft) Loctite 243™ – Screw plug, oil channel, for oil radiator M10x1 15 Nm (11.1 lbf ft) – Screw, unlocking of timing chain ten- M10x1 10 Nm (7.4 lbf ft) sioner –...

  • Page 179: Electrical System

    W5W / socket W2.1x9.5d 12 V 21.7 Tires Front tires Rear tires 120/70 R 17 M/C 58H TL 160/60 R 17 M/C 69H TL Continental Conti Attack SM Continental Conti Attack SM Additional information is available in the Service section under: http://www.ktm.com...

  • Page 180: Fork

    TECHNICAL DATA 21.8 Fork Fork part number 14.18.7L.12 Fork WP Suspension Up Side Down 4860 ROMA Compression damping Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full load capacity 15 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full load capacity...

  • Page 181: Chassis Tightening Torques

    TECHNICAL DATA 21.10 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 stand switch EJOT 2 Nm (1.5 lbf ft) –...
  • Page 182 TECHNICAL DATA – Screw, fork stub 15 Nm (11.1 lbf ft) – Screw, front footrest bracket 25 Nm (18.4 lbf ft) – Screw, fuel tank bracket 15 Nm (11.1 lbf ft) ® Screw, fuel tank, bottom 25 Nm (18.4 lbf ft) Loctite 243™...

  • Page 183: Cleaning/Protective Treatment

    CLEANING/PROTECTIVE TREATMENT 22.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts.

  • Page 184: Checks And Maintenance Steps For Winter Operation

    CLEANING/PROTECTIVE TREATMENT 22.2 Checks and maintenance steps for winter operation Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggres- sive road salt. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

  • Page 185: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear wheel stand. ( p. 10) –...

  • Page 186: 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 188: Wiring Diagram

    WIRING DIAGRAM 25.1 Page 01 of 10 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 602001-01...
  • Page 189 WIRING DIAGRAM Components: EFI control unit Fuse Battery Alternator Starter relay with main fuse Start auxiliary relay Starter motor Voltage regulator Connector for accessory ground (terminal 31) ACC 1 (not assigned) X291 X292 Connector for accessory plus (terminal 30) ACC 1 (not assigned)

  • Page 190: 188

    WIRING DIAGRAM 25.2 Page 02 of 10 ye-rd bl-rd ye-rd ye-rd ye-rd bl-rd bl-rd bl-rd wh-rd wh-rd wh-rd wh-rd br-gr br-gr wh-rd bl-rd ye-rd wh-bl wh-bl ye-rd wh-rd ye-rd ye-rd 602002-01...
  • Page 191 WIRING DIAGRAM Components: EFI control unit EPT control unit Fuse Light relay Power relay Combination instrument Ignition/steering lock Emergency OFF switch, electric starter button X295 Diagnostics connector...

  • Page 192: 190

    WIRING DIAGRAM 25.3 Page 03 of 10 ye-bu ye-bu 602003-01...
  • Page 193 WIRING DIAGRAM Components: Low beam, high beam Fuse Fuse Combination instrument Horn Parking light High beam/low beam switch, horn button, turn signal switch...

  • Page 194: 192

    WIRING DIAGRAM 25.4 Page 04 of 10 wh-gn ye-bu wh-gn ye-bu wh-gn 602004-01...
  • Page 195 WIRING DIAGRAM Components: Front brake light switch Rear brake light switch License plate lamp Brake/tail light...

  • Page 196: 194

    WIRING DIAGRAM 25.5 Page 05 of 10 bl-or ye-bu bl-or 602005-01...
  • Page 197 WIRING DIAGRAM Components: Turn signal relay Combination instrument Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right High beam/low beam switch, horn button, turn signal switch...

  • Page 198: 196

    WIRING DIAGRAM 25.6 Page 06 of 10 bl-rd bl-rd wh-bl wh-bl 602006-01...
  • Page 199 WIRING DIAGRAM Components: Radiator fan temperature switch 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 200: 198

    WIRING DIAGRAM 25.7 Page 07 of 10 br-pu br-pu br-pu br-pu ye-rd br-pu bl-bu bu-gr bu-gr wh-br gn-or wh-bu bl-bu bl-bu ye-rd bu-or ye-rd bl-bu wh-bu gn-or wh-br br-pu bu-or bu-br bu-br wh-gn wh-gn wh-rd wh-rd wh-or wh-or 602007-01...
  • Page 201 WIRING DIAGRAM Components: EFI control unit EPT control unit Fuse Fuse Fuse Fuel pump Motor drive Combination instrument...

  • Page 202: 200

    WIRING DIAGRAM 25.8 Page 08 of 10 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 602008-01...
  • Page 203 WIRING DIAGRAM Components: 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 204: 202

    WIRING DIAGRAM 25.9 Page 09 of 10 ye-gn ye-gn wh-pk wh-pk ye-or ye-or ye-br ye-br bl-gn bl-gn gn-gr bl-gn gn-gr 602009-01...
  • Page 205 WIRING DIAGRAM Components: EFI control unit Throttle position sensor circuit A Intake air temperature sensor Rollover sensor Side stand switch Accelerator position sensor Gear position sensor Oil pressure sensor Combination instrument...

  • Page 206: 204

    WIRING DIAGRAM 25.10 Page 10 of 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 602010-01...
  • Page 207 WIRING DIAGRAM Components: 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 Cable colors: Black Brown Blue Green Gray Light blue Orange...

  • Page 208: 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 corre- sponding properties. KTM recommends Castrol and Motorex ® products. Supplier Castrol –...
  • Page 209 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 210: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Chain lube for road use Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chainlube Road Cleaning and preserving materials for metal, rubber and plastic Guideline –...
  • Page 211 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 ®...

  • Page 212: Special Tools

    SPECIAL TOOLS Bleeder cover Art. no.: 00029013004 201830-10 Bleeder cover Art. no.: 00029013010 201606-10 Bleeding device Art. no.: 00029013100 201491-10 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...
  • Page 213 SPECIAL TOOLS Bleed syringe Art. no.: 50329050000 400058-01 Circlip pliers reverse Art. no.: 51012011000 400059-01 Extractor Art. no.: 58429009000 400073-01 Tool for inner bearing race Art. no.: 58429037043 400082-01 Mounting sleeve Art. no.: 58529005000 400095-01...
  • Page 214 SPECIAL TOOLS Valve spring compressor Art. no.: 59029019000 400101-01 Limit plug gauge Art. no.: 59029026006 400104-01 Extractor Art. no.: 59029033000 400105-01 Feeler gauge Art. no.: 59029041100 400110-01 Hose clamp pliers Art. no.: 60029057000 400142-01...
  • Page 215 SPECIAL TOOLS Pliers for spring band clamp Art. no.: 60029057100 400085-01 Adapter Art. no.: 61029055110 500079-01 Front wheel stand Art. no.: 61029055300 500078-01 Rear wheel stand Art. no.: 61029055400 500077-01 Testing hose Art. no.: 61029093000 201314-01...
  • Page 216 SPECIAL TOOLS Pressure testing tool Art. no.: 61029094000 400149-01 Engine assembly stand Art. no.: 61229001000 200306-01 Work stand Art. no.: 62529055000 400151-01 Support for engine assembly stand Art. no.: 75012001060 400153-01 Holder for engine assembly stand Art. no.: 75012001070 400154-01...
  • Page 217 SPECIAL TOOLS Piston assembly ring Art. no.: 75029015102 400156-01 Extractor Art. no.: 75029021000 400157-01 Assembly screws Art. no.: 75029033000 400158-01 Insertion for piston ring lock Art. no.: 75029035000 400160-01 Work stand adapter Art. no.: 75029036000 400161-01...
  • Page 218 SPECIAL TOOLS 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 Upper part, pressing-out tool Art. no.: 75029047050 400186-01 Under part, pressing-out tool Art. no.: 75029047051 400187-01...
  • Page 219 SPECIAL TOOLS Extractor Art. no.: 75029048000 400162-01 Clamping plate Art. no.: 75029050000 400163-01 Push-out drift Art. no.: 75029051000 400164-01 Floor jack attachment Art. no.: 75029055000 400184-01 Mounting sleeve Art. no.: 75029080000 400165-01...
  • Page 220 SPECIAL TOOLS Gear segment Art. no.: 75029081000 400068-01 Protection cover Art. no.: 75029090000 400167-01 Holding spanner Art. no.: 75029091000 400168-01 Spark plug wrench Art. no.: 75029172000 400170-01 Oil pressure adapter Art. no.: 77329006000 400176-01...
  • Page 221 SPECIAL TOOLS 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 Hook wrench Art. no.: T106S 301085-01 Depth micrometer Art. no.: T107S 300577-10...
  • Page 222 SPECIAL TOOLS Art. no.: T120 201235-10 Pressing tool Art. no.: T1206 200583-10 Pressing tool Art. no.: T1207S 200585-01 Vacuum pump Art. no.: T1240S 200273-10 Pressing tool Art. no.: T129 200584-01...
  • Page 223 SPECIAL TOOLS Protecting sleeve Art. no.: T1401 200635-10 Gripping tool Art. no.: T14026S1 200639-10 Assembly tool Art. no.: T1402S 200634-10 Open-end wrench Art. no.: T14032 200640-10 Clamping stand Art. no.: T1403S 200637-10...
  • Page 224 SPECIAL TOOLS Mounting sleeve Art. no.: T1515 300569-10 Nitrogen filling tool Art. no.: T170S1 300574-10...

  • Page 225: 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 226: Index

    INDEX rear brake, installing ......74 INDEX rear brake, removing ......73 Accessories .
  • Page 227 INDEX clutch cover, removing ..... . 110 piston, checking/measuring ....126 crankshaft and balancer shaft, removing .
  • Page 228 INDEX removing ....... . . 15 Oil screens cleaning ......167, 169 Fork service .
  • Page 229 INDEX Spark plug connector checking ....... . 171 Spoke tension checking .
  • Page 230 *3206153en* 3206153en 10/2012 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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