KTM 2014 690 SMC R EU Repair Manual
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KTM 2014 690 SMC R EU Repair Manual

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REPAIR MANUAL
2014
690 SMC R EU
690 SMC R AU/GB
Art. no. 3206193en

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Summary of Contents for KTM 2014 690 SMC R EU

  • Page 1 REPAIR MANUAL 2014 690 SMC R EU 690 SMC R AU/GB Art. no. 3206193en...
  • 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 Checking the static sag of the shock absorber ..34 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 Checking the riding sag of the shock absorber..35 Symbols used ........... 5 Adjusting the spring preload of the shock Formats used............
  • Page 5 TABLE OF CONTENTS 13 WIRING HARNESS, BATTERY........82 16.3.14 Removing the cylinder head ....... 115 13.1 Removing the battery ........82 16.3.15 Removing the piston ......... 115 13.2 Installing the battery ........82 16.3.16 Removing the water pump impeller..... 116 13.3 Disconnecting the battery ........
  • Page 6 TABLE OF CONTENTS 16.4.35 Disassembling the countershaft....148 20.3 Checking the engine oil pressure ....182 16.4.36 Checking the transmission ......148 20.4 Changing the engine oil and filter, cleaning the oil screens ..........183 16.4.37 Assembling the main shaft......150 20.5 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 Information

    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. 401945-10 Type label The type label  is located on the right side of the frame. 101973-10 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. 402025-10...

  • 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. 232) 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

    Take the weight off the side stand and swing it back up with your foot as far as it will go. Switching off ABS KTM recommends riding with ABS at all times. However, situations may arise in which ABS is not advantageous. Condition Vehicle stationary, engine running.

  • 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 the white adjusting screw all the way clockwise. Info Adjusting screw  is located at the upper end of the left fork leg. The compression damping is located in the left fork leg COMP (white adjust- ing screw).

  • Page 17: Bleeding The Fork Legs

    FORK, TRIPLE CLAMP Bleeding the fork legs Preparatory work – Lean the motorcycle on the side stand. Main work –  Loosen bleeder screw Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. Info Carry out this action on both fork legs.

  • Page 18: Installing The Fork Protector

    FORK, TRIPLE CLAMP Installing the fork protector –  Position the fork protection on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the brake line and cable harness. Put the clamp on, mount and tighten ...

  • Page 19: Installing The Fork Legs

    FORK, TRIPLE CLAMP –  Loosen the screws of the triple clamp. Remove the fork legs from the bottom. G00829-10 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: Disassembling The Fork Legs

    FORK, TRIPLE CLAMP – Position the brake caliper and check that the brake linings are seated correctly. –   Mount screws with spacers but do not tighten. – Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a pressure point.
  • Page 21 FORK, TRIPLE CLAMP – Drain the fork oil. 202309-10 – Clamp the fork leg with the axle clamp. Info Use soft jaws. – Slide the outer tube down. – Pull the spring downwards. Mount the special tool on the hexagonal part. Open-end wrench (T14032) ( p.
  • Page 22 FORK, TRIPLE CLAMP – Remove the cartridge. 202315-10 –  Remove dust boot 202115-13 –  Remove lock ring Info The lock ring has a beveled end where a screwdriver can be applied. 202005-12 –  Heat up the outer tube in area of the lower sliding bushing.

  • Page 23: Checking The Fork Legs

    FORK, TRIPLE CLAMP 6.10 Checking the fork legs Condition Fork disassembled. – Check the inner tube and axle clamp for damage. » If there is damage: – Change the inner tube. 202134-10 – Measure the outside diameter at several locations on the inner tube. Outside diameter of inner tube 47.975…...

  • Page 24: Assembling The Fork Legs

    FORK, TRIPLE CLAMP – Check the spring length. Guideline Spring length with preload spacer(s) 463 mm (18.23 in) » If the measured value is greater than the specified value: – Reduce the thickness of the preload spacers. » If the measured value is less than the specified value: –...
  • Page 25 FORK, TRIPLE CLAMP –  Heat up the outer tube in area of the lower sliding bushing. Guideline 50 °C (122 °F) – Slide the outer tube onto the inner tube. – Hold the lower sliding bushing with the longer side of the special tool. Mounting tool (T14040S) ( p.
  • Page 26 FORK, TRIPLE CLAMP –  Mount and tighten screw of the cartridge. Guideline Screw, cartridge M12x1 25 Nm (18.4 lbf ft) 202314-11 –  Mount special tool on the cartridge; remove pin of the special tool. Gripping tool (T14026S1) ( p.
  • Page 27 FORK, TRIPLE CLAMP – Push the outer tube upward. – Clamp the fork in the area of the lower triple clamp. Clamping stand (T1403S) ( p. 240) – Lubricate the O-ring of the Preload Adjuster. Lubricant (T511) ( p. 226) –...

  • Page 28: Checking The Steering Head Bearing Play

    FORK, TRIPLE CLAMP Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seri- ously alter the vehicle's ride behavior. – Extreme modifications to the adjustment of the suspension compo- nents can cause a serious deterioration in the handling characteris- tics and overload some components.
  • Page 29 FORK, TRIPLE CLAMP Main work –   Loosen screws . Remove screw –  Loosen and retighten screw Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) – Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. –...

  • Page 30: Handlebar, Controls

    HANDLEBAR, CONTROLS Handlebar position  In the upper triple clamp, there are 2 drill holes separated by a distance of 15 mm (0.59 in)  Hole distance The drill holes on the handlebar holder are centered and separated by a distance ...
  • Page 31 HANDLEBAR, CONTROLS –  Remove screws . Take off the side cover. G00779-10 – Remove the cable binder. G00781-10 –  Remove screw – Push the trim aside. G00780-10 –  Disconnect plug-in connector – Expose the cable of the accelerator position sensor. G00782-10 –...
  • Page 32 HANDLEBAR, CONTROLS –  Remove screws – Take off the handlebar guard. G00785-10 –  Remove screws G00786-10 –   Pull throttle grip and accelerator position sensor from the handlebar. G00787-10 –   Position throttle grip and accelerator position sensor on the handlebar.
  • Page 33 HANDLEBAR, CONTROLS –  Tighten screw G00784-10 –  Connect plug-in connector – Route the wiring harness of the accelerator position sensor without tension. G00782-10 – Secure the cable with the cable binders. G00781-10 – Position the combination instrument in the holder. –...
  • Page 34 HANDLEBAR, CONTROLS – Secure the cable with the cable binder. G00778-10 Finishing work – Install the headlight mask with the headlight. ( p. 102) – Check the headlight setting. ( p. 101) – Reset the control unit engine electronics KHRS. –...

  • Page 35: 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 36: 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 37: 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. 34) – 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 38: 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. 61) – Take off the side cover. ( p. 62) – Remove the shock absorber. ( p.

  • Page 39: Installing The Shock Absorber

    SHOCK ABSORBER, SWINGARM – Lift the rear fairing. –  Remove screws G00742-13 –  Remove screws G00818-11 –  Loosen screw –  Remove screw –  Remove screw G00825-11 – Fold the rear upward. –  Take out shock absorber toward the top.
  • Page 40 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 41: Servicing The Shock Absorber

    SHOCK ABSORBER, SWINGARM – Mount the seat. ( p. 62) – 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 42: Dismantling The Damper

    SHOCK ABSORBER, SWINGARM 8.13 Dismantling the damper Preparatory work – Remove the spring. ( p. 39) 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 43: 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. 39) – Dismantle the damper. ( p. 40) Main work – Clamp the piston rod with the heim joint in a vise.

  • Page 44: 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 45: 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 46: Installing The Heim Joint

    SHOCK ABSORBER, SWINGARM –  Place special tool underneath and press out the heim joint with special tool  Pressing tool (T1207S) ( p. 238) 200580-10 8.17 Installing the heim joint – Place special tool  underneath and press in the heim joint as far as the center ...

  • Page 47: Assembling The Piston Rod

    SHOCK ABSORBER, SWINGARM 8.18 Assembling the piston rod Preparatory work – Check the damper. ( p. 42) 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 48: 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. 42) – Assemble the piston rod. ( p. 45) Main work –...
  • Page 49 SHOCK ABSORBER, SWINGARM –  Grease O-ring of the seal ring retainer. Lubricant (T158) ( p. 226) – 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 50: 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 51 SHOCK ABSORBER, SWINGARM –  Measure distance between the floating piston and reservoir hole with the spe- cial tool. Depth micrometer (T107S) ( p. 238) 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- ...

  • Page 52: 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 –...

  • Page 53: Installing The Spring

    SHOCK ABSORBER, SWINGARM – Clamp special tool in the vise. Nitrogen filling tool (T170S1) ( p. 240) – 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 54 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 55: 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. 61) –...

  • Page 56: Installing The Manifold

    EXHAUST Installing the manifold Main work – Position the manifold with the seals. – Position the spacer. –  Mount and tighten nuts with the gasket. Guideline Nut, manifold on cylinder 25 Nm Copper paste head (18.4 lbf ft) G00813-11 –...

  • Page 57: Removing The Main Silencer

    EXHAUST Removing the main silencer 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 – Raise the motorcycle with the work stand. ( p.

  • Page 58: Installing The Main Silencer

    EXHAUST Installing the main silencer Main work – Position the main silencer. – Mount and tighten screw  Guideline Screw, main silencer holder 25 Nm (18.4 lbf ft) G00817-11 – Position the screw clamp. –  Tighten screw Guideline Screw, main silencer 12 Nm Copper paste clamp...

  • Page 59: Air Filter

    AIR FILTER 10.1 Removing the air filter Preparatory work – Remove the seat. ( p. 61) 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 60 AIR FILTER Main work –  Remove screws – Take off the voltage regulator and hang it to the side in a de-energized state. G00792-10 –  Remove screws G00793-10 –  Remove screws G00794-10 –  Loosen hose clip G00795-10 –...

  • Page 61: Installing The Air Filter Box

    AIR FILTER –  Take off control unit and hang to the side. G00798-10 – Remove the cable binder. –  Disconnect connector of the intake air temperature sensor. – Raise the air filter box at the rear. – Take off the air filter box. G00799-10 10.4 Installing the air filter box...
  • Page 62 AIR FILTER –  Mount and tighten hose clip G00795-11 –  Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) G00794-11 –  Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) G00793-11 –...

  • Page 63: 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 64: Mounting The Seat

    FUEL TANK, SEAT, TRIM 11.4 Mounting the seat 101988-10 –   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 65 FUEL TANK, SEAT, TRIM Condition The fuel tank is completely full. 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.

  • Page 66: Changing The Fuel Filter

    FUEL TANK, SEAT, TRIM 11.8 Changing the fuel filter 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 67 FUEL TANK, SEAT, TRIM –  Remove screws and the splash protector. G00819-10 –  Remove screws – Pull out the fuel pump. S00113-10 –  Disconnect both fuel hose connections –  Unplug connector . Remove the fuel pump. G00820-10 –...
  • Page 68 FUEL TANK, SEAT, TRIM –  Connect both fuel hose connections –  Attach connector G00820-10 – 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)

  • Page 69: Changing The Fuel Pump

    FUEL TANK, SEAT, TRIM – Disconnect the battery. ( p. 83) – Mount the seat. ( p. 62) – Set the clock. ( p. 99) 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.
  • Page 70 FUEL TANK, SEAT, TRIM –  Remove screws and the splash protector. G00819-10 –  Remove screws – Pull out the fuel pump. S00113-10 –  Disconnect both fuel hose connections –  Disconnect plug-in connector . Disconnect the fuel pump. –...
  • Page 71 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) G00817-12 –  Mount and tighten screws Guideline Screw, side cover 5 Nm (3.7 lbf ft) G00816-12 Finishing work –...

  • Page 72: 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 73: 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 74: 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 75: Installing The Front Wheel

    WHEELS – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. –  Remove spacers 101998-10 12.6.2 Installing the front wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. –...

  • Page 76: Removing The Brake Disc Of The Front Brake

    WHEELS – Take the motorcycle off of the front wheel stand. ( p. 11) – Pull the front wheel brake and push down hard on the fork several times to align the fork legs. –  Tighten screws Guideline Screw, fork stub 15 Nm (11.1 lbf ft) 101999-10...

  • Page 77: Installing The Rear Wheel

    WHEELS –  Pull out wheel spindle to the point where the chain adjuster is no longer in con- tact with the adjusting screw. – Push the rear wheel forwards as far as possible and take the chain off the rear sprocket.

  • Page 78: Removing The Brake Disc Of The Rear Brake

    WHEELS – Push the rear wheel forward as far as possible and lay the chain on the rear sprocket. –   Mount the wheel spindle, chain adjuster , and nut Guideline In order for the rear wheel to be correctly aligned, the markings on the left and right chain adjusters must be in the same position relative to the reference ...

  • Page 79: Checking The Chain Tension

    WHEELS 12.7.5 Checking 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 80: Adjusting Chain Guide

    WHEELS Main work –  Loosen nut –  Loosen nuts –  Adjust the chain tension by turning adjusting screws on the left and right. Guideline Chain tension 5 mm (0.2 in) Turn the left and right adjusting screws ...
  • Page 81 WHEELS –  Pull on the upper section of the chain with the specified weight Guideline Weight of chain wear measurement 15 kg (33 lb.) 0 0 A –  Measure distance of 18 chain links in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 82: Cleaning The Chain

    WHEELS – Check the chain guide for wear. Info Wear is visible on the front of the chain guide. » If the light part of the chain guide is worn: – Change the chain guide. 400985-01 – Check that the chain guide is firmly seated. »...
  • Page 83 WHEELS Main work –  Check bearing » If the bearing is damaged or worn: – Replace the bearings. – Check rubber dampers  of the rear hub for damage and wear. » If the rubber dampers of the rear hub are damaged or worn: –...

  • Page 84: 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 85: Disconnecting The Battery

    Environmental hazard The battery contains elements that are harmful to the environment. – 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.

  • Page 86: Checking The Charging Voltage

    WIRING HARNESS, BATTERY 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 Even when there is no load on the battery, it still loses power steadily. The charging level and the method of charging are very important for the service life of the battery.

  • Page 87: Checking The Quiescent Current

    WIRING HARNESS, BATTERY – Measure the voltage between the specified points. Measuring point Plus (+) – Measuring point Ground (−) Charging voltage 5,000 rpm 13.5… 15.0 V » If the displayed value is less than the specified value: – Check the plug-in connections from the alternator to the voltage regulator. –...

  • Page 88: Changing Fuses Of Individual Power Consumers

    WIRING HARNESS, BATTERY Main work –  Remove protection covers 102006-10 –  Remove a defective main fuse with needle nose pliers. Info A defective fuse is indicated by a burned-out fuse wire   A reserve fuse is located in the starter relay. –...

  • Page 89: Adjusting The Engine Characteristic

    WIRING HARNESS, BATTERY – Remove the defective fuse. Guideline Fuse 1 - 10 A - ignition, combination instrument, clock, EFI control unit Fuse 2 - 10 A - ignition, combination instrument, EFI control unit Fuse 3 - 10 A - fuel pump Fuse 4 - 10 A - radiator fan Fuse 5 - 10 A - horn, brake light, turn signal Fuse 6 - 15 A - high beam, low beam, parking light, tail light, license plate lamp...
  • Page 90 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 91: 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 92: 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 93: 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. » If the brake fluid has dropped below marking  – Add front brake fluid. ( p.

  • Page 94: 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 95: Checking The Rear Brake Linings

    BRAKE SYSTEM – Open the bleeder screw again until brake fluid stops emerging. 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.
  • Page 96 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 97: 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 98: 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. 96) 101992-10 14.12 Adding rear brake fluid Warning Danger of accidents Failure of the brake system.

  • Page 99: 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 100 BRAKE SYSTEM – Open the bleeder screw again until brake fluid stops emerging. 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.

  • Page 101: 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 102: 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. 401446-01 15.1.5 Setting the wheel circumference...

  • Page 103: 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 104: 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. 102026-11 – Remove the cloth from the fender and position the headlight mask. ...

  • Page 105: 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 106: 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 107: Engine

    ENGINE 16.1 Removing the engine Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. ( p. 61) – Disconnect the battery. ( p. 83) – Raise the motorcycle with the work stand. ( p.
  • Page 108 ENGINE – Take off the engine sprocket. –  Remove screws –  Remove cable binder – Take off the clutch slave cylinder with the gasket and hang it to the side. Info Do not kink the clutch line. Do not activate the clutch lever if the clutch slave cylinder has been removed.

  • Page 109: Installing The Engine

    ENGINE –   Detach connector of the oil pressure sensor. Remove screw –  Release connection . Remove the line with the oil pressure sensor. G00844-10 –  Remove screws . Remove the engine bearer. G00845-10 – Position the floor jack under the engine and fix it using the special tool. Floor jack attachment (75029055000) ( p.
  • Page 110 ENGINE Main work – Position the engine in the frame. G00848-10 – Mount swingarm pivot. –  Mount the screw of swingarm pivot but do not tighten yet. –  Mount screw connection of the lower engine attachment but do not tighten yet. Info You should have an assistant for this step.
  • Page 111 ENGINE – Position the hoses of the engine breather, the SAS, and the oil return line. Mount  the spring band clamp using the special tool. Pliers for spring band clamp (60029057100) ( p. 231) G00843-11 – Attach the spark plug connectors. –...
  • Page 112 ENGINE – Mount the engine sprocket with the chain. – Position the new lock washer and mount nut but do not tighten yet. – Position the rear wheel. – Mount the chain adjuster and nut. – Push the rear wheel forward so that the chain adjusters rest against the tensioning ...

  • Page 113: Disassembling The Engine

    – Perform the initialization run. ( p. 189) – 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. 181) –...

  • Page 114: Removing The Starter Motor

    ENGINE 16.3.3 Removing the starter motor –  Remove oil throttle – Take off the starter motor. 305512-10 16.3.4 Removing the valve cover –  Remove screws – Take off the valve cover with the valve cover seal. 305517-10 16.3.5 Removing the alternator cover –...

  • Page 115: Removing The Gear Position Sensor

    ENGINE 16.3.7 Removing the gear position sensor –  Remove screws with the washers. – Remove gear position sensor  with the O-ring. 201959-11 16.3.8 Removing the oil filter –  Remove screws – Take off the oil filter cover with the O-ring. –...

  • Page 116: Removing The Spark Plugs

    ENGINE –  Remove screw Info Look through the hole to check that the position hole of the balancer shaft is visible. –  Screw in special tool Engine blocking screw (77329010000) ( p. 237) 305532-10 16.3.11 Removing the spark plugs –...

  • Page 117: Removing The Cylinder Head

    ENGINE 16.3.14 Removing the cylinder head –  Remove screws 305544-10 –  Loosen screws diagonally and remove them. – Take off the cylinder head. 305545-10 16.3.15 Removing the piston –  Take off the cylinder head gasket –  Remove screw –...

  • Page 118: Removing The Water Pump Impeller

    ENGINE 16.3.16 Removing the water pump impeller –  Remove screws . Take off the water pump cover. 305556-10 –  Remove screw –  Remove water pump impeller – Take off the water pump cover seal. Info Ensure the locating pins remain in place. 305557-10 –...

  • Page 119: Removing The Timing Chain Rails

    ENGINE –  Mount the special tool on the rotor. Extractor (58429009000) ( p. 229) – Hold it tight using the special tool and pull off the rotor by turning the screw in. – Remove the special tool. 305562-10 16.3.18 Removing the timing chain rails –...

  • Page 120: Removing The Ignition Pulse Generator

    ENGINE –  Pull off the timing chain sprocket with special tool Extractor (59029033000) ( p. 230) 305571-10 16.3.20 Removing the ignition pulse generator –  Remove screws –  Pull cable sleeve out of the engine case. – Remove the ignition pulse generator. 305572-10 16.3.21 Removing the clutch cover –...

  • Page 121: Removing The Clutch Basket

    ENGINE 16.3.23 Removing the clutch basket –  Clamp the antihopping clutch with special tool Assembly screws (75029033000) ( p. 233) Info Apply the special tool with the hand only, do not use another tool. 305576-10 –  Loosen screws diagonally and remove them with their spring retainers and clutch springs.

  • Page 122: Removing The Primary Gear

    ENGINE –  Remove stepped washer 305581-10 –  Remove half washers –  Take off the clutch basket 305582-10 –   Remove needle bearing and supporting plate 305583-10 16.3.24 Removing the primary gear –  Position special tool Protection cover (75029090000) ( p.

  • Page 123: Removing Shift Shaft

    ENGINE –  Remove lock ring –  Remove torque limiter with the washers and needle bearing. 305615-10 –  Take off freewheel gear 305616-10 –   Remove woodruff key and both needle bearings 305617-10 16.3.26 Removing shift shaft –...

  • Page 124: Removing Locking Lever

    ENGINE 16.3.28 Removing locking lever –  Remove screw – Take off locking lever  with the sleeve and spring. 305622-10 16.3.29 Removing the oil pumps –   Remove lock washers and normal washers from both oil pumps. – ...

  • Page 125: Removing The Left Engine Case

    ENGINE –  Remove screws – Take off the oil pump cover. 305628-10 –  Remove oil pump shaft with the internal rotors. –  Remove external rotor 305629-10 16.3.30 Removing the left engine case – Remove screws  – Swing the left section of the engine case up and remove the nut or screw of the engine fixing arm.

  • Page 126: Removing The Crankshaft And Balancer Shaft

    ENGINE 16.3.31 Removing the crankshaft and balancer shaft –   Remove balancer shaft and crankshaft 305637-10 16.3.32 Removing the transmission shafts –  Remove shift rail 305638-10 –  Swing shift forks to one side. –  Remove shift drum 305639-10 –...

  • Page 127: Work On Individual Parts

    ENGINE –  Remove transmission shafts Info The stop disk of the countershaft usually sticks to the bearing. –  Take off the O-ring of countershaft 305642-10 16.4 Work on individual parts 16.4.1 Work on the right section of the engine case –...

  • Page 128: Work On The Left Section Of The Engine Case

    ENGINE Info If the bearings are not firmly seated after cooling, it is likely that they will rotate in the engine case when warm. In this case, the engine case must be renewed. – Position all bearing locks. Mount and tighten the screws. Guideline Locking screw for bearing 6 Nm...
  • Page 129 ENGINE – Press out the shaft seal ring of the crankshaft from the outside to the inside. – Press in the shaft seal ring of the crankshaft from the inside to the outside with the open side facing out. Info The shaft seal ring must be flush on the outside.

  • Page 130: Work On The Clutch Cover

    ENGINE Info The membrane support plate is curved and must point away from the mem- brane. An incorrectly installed membrane support plate results in loss of perfor- mance and increased oil consumption or leaks. Do not apply thread locker between the membrane and the membrane sup- port plate since this would impair their function.
  • Page 131 ENGINE Main work –  Position the crankshaft with special tool in the press. Under part, pressing-out tool (75029047051) ( p. 235) –  Position special tool between the crankwebs. Upper part, pressing-out tool (75029047050) ( p. 234) – Press the crank pin out of the upper crankweb with the push-out drift of the special tool.

  • Page 132: Checking Crankshaft Run-Out At Bearing Pin

    ENGINE –  Position special tool with the heel at the bottom. Pressing device for crankshaft, complete (75029047000) ( p. 234) – Press the upper crankweb in as far as possible. Info The press mandrel must be applied above the crank pin. –...

  • Page 133: Installing Crankshaft Bearing Inner Ring

    ENGINE – Place the drive wheel on the crankshaft.  The dowel of the crankshaft must fit in the drill hole  The side of the drive wheel with the punch mark must be visible after  assembly, and the side with the bevel must be in contact with the crankweb.

  • Page 134: Cylinder - Nikasil ® Coating

    ENGINE » If the measured value does not equal the specified value: – Remove the crankshaft. – Remove the crankshaft bearing inner ring. ( p. 128) – Calculate the thickness of the compensation shims. – Add or remove compensation shims equally on both sides. Info If the axial clearance is too small, remove compensation shims.

  • Page 135: Checking/Measuring The Piston

    ENGINE –  The cylinder size is marked on the side of the cylinder. 305588-10 – Check the sealing area of the cylinder head for distortion using a straight edge and the special tool. Feeler gauge (59029041100) ( p. 230) ≤...

  • Page 136: Checking Piston Ring End Gap

    ENGINE – Measure the piston at the piston skirt, at right angles to the piston pin, at a  distance Guideline 31.5 mm (1.24 in)  Distance Piston - diameter Size I 101.955… 101.965 mm (4.01397… 4.01436 in) Size II 101.965…...

  • Page 137: Replacing Autodecompressor

    ENGINE » If the measured value does not meet specifications: – Change the oil pump and, if necessary, the engine case. 305661-10 –  Check the internal rotor and external rotor of oil pumps for damage and wear. » If there is damage or wear: –...

  • Page 138: Preparing Timing Chain Tensioner For Installation

    ENGINE –  Disconnect the autodecompression spring. Loosen the screw and remove it together with the autodecompression spring and the autodecompression weight  300109-10 – When assembling, first connect the autodecompression spring and then insert the screw through the autodecompression weight. ...

  • Page 139: Checking The Timing Assembly

    ENGINE 16.4.19 Checking the timing assembly 305601-10 – Clean all parts well. –  Check timing chain gear for damage and wear. » If there is damage or wear: – Change the timing chain gear/timing chain sprocket. –  Check timing chain tensioning rail for damage and wear.

  • Page 140: Removing The Rocker Arm

    ENGINE 16.4.20 Removing the rocker arm –  Take shims out of the valve spring retainers and lay them to one side according to their normal built-in position. 305664-10 –  Remove screws 305665-10 –   Screw a suitable screw into the rocker arm shafts .

  • Page 141: Removing The Valves

    ENGINE –  Remove the small camshaft bearing using special tool Insert for bearing puller (15112018100) ( p. 228) Bearing puller (15112017000) ( p. 228) 305670-10 –  Press in the small camshaft bearing as far as possible using special tool Push-in drift (75029044020) ( p.

  • Page 142: Checking The Valves

    ENGINE 16.4.23 Checking the valves – 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: – Change the valve. 305605-10 –...

  • Page 143: Installing The Valves

    ENGINE – Check the sealing area of the cylinder for distortion using a straight edge and the special tool. Feeler gauge (59029041100) ( p. 230) ≤ 0.10 mm (≤ 0.0039 in) Cylinder/cylinder head - sealing area distortion » If the measured value does not equal the specified value: –...

  • Page 144: Installing The Rocker Arm

    ENGINE 16.4.28 Installing the rocker arm –   Position rocker arm and push in the rocker arm shafts Info Make sure that the tapped hole of the rocker arm shaft is facing outward.  The small drill hole and the flat surface must face upward. –...

  • Page 145: Checking The Clutch

    ENGINE – Take the clutch out of the vise and lay it on a clean workbench with the outer  clutch hub facing down. –   Take the inner clutch hub and release springs out of the outer clutch ...

  • Page 146: Preassembling The Antihopping Clutch

    ENGINE –  Place push rod on a level surface and check it for run-out. » If there is run-out: – Change the push rod. –  Check the length of clutch springs Clutch spring - length 31.5… 33.5 mm (1.24… 1.319 in) »...

  • Page 147: Checking The Shift Mechanism

    ENGINE – Position the trimmed clutch facing disc with the recess for the pretension ring on the outer clutch hub. – Beginning with the coated intermediate clutch disc, position all further clutch fac- ing discs and intermediate clutch discs alternately. –...

  • Page 148: Preassembling The Shift Shaft

    ENGINE –  Check the seat of the shift drum in bearings » If the shift drum is not seated correctly: – Change the shift drum and/or the bearing. –  Check bearing for stiffness and wear. » If the bearings do not move freely or are worn: –...

  • Page 149: Disassembling The Main Shaft

    ENGINE 16.4.34 Disassembling the main shaft 306232-10 – 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 –...

  • Page 150: Disassembling The Countershaft

    ENGINE 16.4.35 Disassembling the countershaft 306233-10 – Fix the countershaft in the vise with the geared end facing downward. Guideline Use soft jaws –   Remove stop disk and first-gear idler gear –   Remove needle bearing and stop disk –...
  • Page 151 ENGINE 305674-10 –  Check needle bearings for damage and wear. » If there is damage or wear: – Change the needle bearing. – Check the pivot points of main shaft  and countershaft  for damage and wear. » If there is damage or wear: –...

  • Page 152: Assembling The Main Shaft

    ENGINE –  Check stop disks for damage and wear. » If there is damage or wear: – Change the stop disk. –  Use new lock rings in every repair job. –  Check bearing bush for damage and wear. »...

  • Page 153: Assembling The Countershaft

    ENGINE –  Push on the third/fourth-gear sliding gear with the small gear wheel facing downward. –  Position special tool on the transmission shaft. Mounting tool for lock ring (75029005000) ( p. 233) –    Position lock ring on special tool and push down with sleeve The lock ring engages in the groove of the transmission shaft.

  • Page 154: Checking The Starter Drive

    ENGINE –  Mount the sixth-gear sliding gear with the shift groove facing upward. –  Position special tool on the transmission shaft. Mounting tool for lock ring (75029005000) ( p. 233) –    Position lock ring on special tool and push down with sleeve The lock ring engages in the groove of the transmission shaft.

  • Page 155: Checking Freewheel

    ENGINE – Change the freewheel gear and/or the bearing. –  Check freewheel when removed for damage and wear. » If there is damage or wear: – Change the freewheel. – Check the toothing of starter motor  for damage and wear. »...

  • Page 156: Assembling The Engine

    ENGINE –  Install the expansion ring 300128-11 –  Make sure that all lugs of the expansion ring locate in the slits of the freewheel. Info If necessary, use a screwdriver to ease them in. 300130-10 –  Insert the lock ring into the groove with suitable pliers and check that it is seated correctly.

  • Page 157: Installing Crankshaft And Balancer Shaft

    ENGINE –   Mount the upper shift fork , the middle shift fork , and the lower shift fork  Info  For easier assembly of the middle shift fork , lift the sliding gear of the third/fourth gear. 305643-10 –...

  • Page 158: Installing The Left Engine Case

    ENGINE – Push the crankshaft into the bearing seat and take off the special tool. – Grease the shaft seal rings of the balancer shaft. – Push the balancer shaft  into the bearing seat and take off the special tool. ...

  • Page 159: Installing The Oil Pumps

    ENGINE 16.5.4 Installing the oil pumps – Mount the pin and internal rotor on the oil pump shaft. – Position the external rotor in the engine case. The marking is not visible after mounting. –   Mount the oil pump shaft with internal rotor –...

  • Page 160: 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 M6x20 10 Nm Loctite ® 243™ (7.4 lbf ft) 305623-10 16.5.6 Installing shift drum locating –...

  • Page 161: Installing The Primary Gear

    ENGINE –  Position freewheel gear 305616-11 –  Mount the needle bearing and torque limiter with the washer. –  Mount lock ring 305615-11 –  Mount the starter idler gear with the washer. –  Mount lock ring 305614-11 16.5.9 Installing the primary gear...
  • Page 162 ENGINE –  Mount clutch basket Info Turn the clutch basket and oil pump gear wheels backwards and forwards slightly to help them mesh more easily. –  Mount half washers with the sharp edge facing outward. Info Grease the half washers to ease assembly. 305582-11 –...

  • Page 163: Installing The Spacer And Spring

    ENGINE –  Position pressure cap –  Mount and tighten screws with the spring retainers and clutch springs. Guideline Screw, clutch spring M5x25 6 Nm (4.4 lbf ft) Info Ensure that all clutch springs have a blue color coding. 305577-11 –...

  • Page 164: Installing The Ignition Pulse Generator

    ENGINE 16.5.13 Installing the ignition pulse generator – Position the ignition pulse generator. –  Mount screws but do not tighten yet. Guideline Loctite ® 243™ Screw, crankshaft position M6x16 10 Nm sensor (7.4 lbf ft) –  Position the cable and position cable sleeve in the engine case.

  • Page 165: Installing The Rotor

    ENGINE –  Position the timing chain guide rail from above. – Insert the support bushing into the timing chain securing guide. –  Mount and tighten screws Guideline Loctite 243™ Screw, timing chain guide M6x30 10 Nm ® rail (7.4 lbf ft) Screw, timing chain ten- M6x30...

  • Page 166: Setting Engine To Top Dead Center

    ENGINE 16.5.18 Setting engine to top dead center –  Set the crankshaft to top dead center and lock it with the special tool Engine blocking screw (77329010000) ( p. 237) 305560-10 16.5.19 Mounting the water pump cover –  Mount form washer 305558-11 –...
  • Page 167 ENGINE – Position the piston on the cylinder using the special tool. – Push the piston carefully into the cylinder from above. The piston rings should not become caught; otherwise, they may be damaged. 302601-10 –  Ensure that piston marking faces the outfeed side.

  • Page 168: Installing The Cylinder Head

    ENGINE – Insert the special tool and firmly press it toward the piston. – Turn the special tool counterclockwise, thereby pressing the piston pin retainer into the groove. Insertion for piston ring lock (75029035000) ( p. 233) – Make sure that the piston pin retainer is seated correctly on both sides. 300038-10 –...

  • Page 169: Installing The Camshafts

    ENGINE 16.5.22 Installing the camshafts – Lay the timing chain over the camshaft. Push the camshaft into the bearing seats. The crankshaft is at top dead center.   The middle drill hole of camshaft and the drill hole of cylinder head are aligned.

  • Page 170: Checking Valve Clearance

    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. 237) The timing chain tensioner unlocks. – Mount and tighten screw ...

  • Page 171: Adjusting The Valve Clearance

    ENGINE 16.5.25 Adjusting the valve clearance –  Remove screws Info Make sure that the crankshaft is at top dead center. 305535-10 –   Screw suitable screws into the rocker arm shafts – Remove the rocker arm shafts and take off the rocker arm. 305536-10 –...

  • Page 172: Installing The Spark Plugs

    ENGINE 16.5.26 Installing the spark plugs –  Mount and tighten spark plug using the special tool. Guideline Spark plug inside M12x1.25 18 Nm (13.3 lbf ft) Spark plug wrench (75029172000) ( p. 236) –  Mount and tighten spark plug using the special tool.

  • Page 173: Installing The Gear Position Sensor

    ENGINE 16.5.29 Installing the gear position sensor –  Mount gear position sensor with the O-ring.  engages in drill hole  201958-10 –  Mount and tighten screws with the washers. Guideline Screw, gear position sen- M5x16 5 Nm Loctite ®...

  • Page 174: Installing Oil Screens

    ENGINE – Position the alternator cover. –  Mount and tighten screws Guideline Screw, alternator cover M6x25 10 Nm (7.4 lbf ft) –  Mount and tighten screws Guideline Screw, alternator cover M6x30 10 Nm (7.4 lbf ft) 305519-10 – ...

  • Page 175: Installing The Valve Cover

    ENGINE 16.5.34 Installing the valve cover – Position the valve cover with the gasket. –  Mount and tighten screws Guideline Screw, valve cover 10 Nm (7.4 lbf ft) 305517-10 16.5.35 Removing the engine from the engine assembly stand – Remove the engine from the engine assembly stand.

  • Page 176: 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 177: Shift Mechanism

    SHIFT MECHANISM 18.1 Changing the gear position sensor Preparatory work – Raise the motorcycle with a lift stand. ( p. 11) Main work –  Remove screw . Take off the engine sprocket cover. G00772-10 –  Remove cable binder G00773-10 –...
  • Page 178 SHIFT MECHANISM –  Lubricate O-ring of the new gear position sensor. – Position the gear position sensor.   engages in drill hole G00777-10 –  Mount and tighten screws Guideline Loctite ® 243™ Screw, gear position sen- M5x16 5 Nm (3.7 lbf ft) G00776-10...

  • Page 179: Programming The Gear Position Sensor

    SHIFT MECHANISM 18.2 Programming the gear position sensor Condition The diagnostics tool is connected and running. Preparatory work – Reset the control unit engine electronics KHRS. Main work – Execute "Engine electronics" > "Functions" > "Program the gear position sensor". –...

  • Page 180: Water Pump, Cooling System

    WATER PUMP, COOLING SYSTEM 19.1 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 181: 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 182: 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. 224) Alternative 2 Coolant (mixed ready to use) ( p.

  • Page 183: Lubrication System

    LUBRICATION SYSTEM 20.1 Oil circuit 402053-60 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 184: 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 185: Changing The Engine Oil And Filter, Cleaning The Oil Screens

    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 186: 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 20.6 Removing the oil filter Warning...

  • Page 187: Cleaning The Oil Screens

    LUBRICATION SYSTEM 20.8 Cleaning the oil screens Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 188: Filling Up With Engine Oil

    LUBRICATION SYSTEM 20.9 Filling up with engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. Main work –  Remove filler plug with O-ring from the clutch cover and add engine oil. 0 0 1 Engine oil 1.70 l (1.8 qt.)

  • Page 189: Ignition

    IGNITION 21.1 Alternator - checking the stator winding Condition The stator is disconnected. Preparatory work – Remove the seat. ( p. 61) – Take off the side cover. ( p. 62) Main work Stator winding, measurement I - check the resistance –...

  • Page 190: Ignition Coil - Checking The Secondary Winding

    IGNITION Ignition coil – checking the secondary winding 21.3 Condition Ignition coil cylinder 1 is disconnected. Spark plug connector cylinder 1 has been removed. Preparatory work – Remove the seat. ( p. 61) – Take off the side cover. ( p.

  • Page 191: Throttle Valve Body

    THROTTLE VALVE BODY 22.1 Performing the initialization run Condition The diagnostics tool is connected and running. – Execute "Engine electronics" > "Functions" > "Delete adaptation values". The adaptation values are deleted. – Switch off ignition. – Disconnect the diagnostics tool. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.

  • Page 192: Technical Data

    TECHNICAL DATA 23.1 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 12.6:1 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 193 TECHNICAL DATA Valve - sealing seat width Intake 1.60 mm (0.063 in) 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 ≤...

  • Page 194: Engine Tightening Torques

    TECHNICAL DATA 23.3 Engine tightening torques Loctite ® 243™ Screw, membrane fixation 2 Nm (1.5 lbf ft) – Hose clamp, intake flange 2.5 Nm (1.84 lbf ft) Oil nozzle for conrod bearing lubrica- 2 Nm (1.5 lbf ft) Loctite ® 243™...

  • Page 195: Capacities

    TECHNICAL DATA Cylinder head screw Tightening sequence: Lubricated with engine oil Tighten diagonally, begin- ning with the rear screw on the timing 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) Step 4 60 Nm (44.3 lbf ft)

  • Page 196: Chassis

    TECHNICAL DATA 23.5 Chassis Frame Lattice frame made of chrome molybdenum steel tubing, powder-coated Fork WP Suspension 4860 ROTA SPLIT WP Suspension 4618 with Pro‑Lever deflector Shock absorber Suspension travel Front 215 mm (8.46 in) Rear 250 mm (9.84 in) Brake system Front Disc brake with radially screwed four-piston brake caliper, float-...

  • Page 197: 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 23.8 Fork Fork part number 14.18.8N.25 WP Suspension 4860 ROTA SPLIT...

  • Page 198: Chassis Tightening Torques

    TECHNICAL DATA Static sag 20… 25 mm (0.79… 0.98 in) Riding sag 70… 80 mm (2.76… 3.15 in) Fitted length 395 mm (15.55 in) Shock absorber fluid Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 225) 23.10 Chassis tightening torques –...
  • Page 199 TECHNICAL DATA – Screw, voltage regulator 8 Nm (5.9 lbf ft) – Screw, wheel speed sensor 6 Nm (4.4 lbf ft) Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite ® 2701™ – Remaining nuts, chassis 25 Nm (18.4 lbf ft) –...

  • Page 200: Cleaning/Protective Treatment

    CLEANING/PROTECTIVE TREATMENT 24.1 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 201: Checks And Maintenance Steps For Winter Operation

    CLEANING/PROTECTIVE TREATMENT – Treat all plastic parts and powder-coated parts with a mild cleaning and care agent. Special cleaner for glossy and matte paint finishes, metal and plastic surfaces p. 227) – Lubricate the ignition/steering lock. Universal oil spray ( p.

  • Page 202: 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 203: 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 204: Wiring Diagram

    WIRING DIAGRAM 27.1 Page 01 of 11 G00401-01...
  • Page 205 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 206: 204

    WIRING DIAGRAM 27.2 Page 02 of 11 G00402-01...
  • Page 207 WIRING DIAGRAM Components: EFI control unit Fuse Fuse Light relay Power relay Fuel pump Combination instrument Ignition/steering lock Emergency OFF switch, electric starter button X295 Diagnostics connector...

  • Page 208: 206

    WIRING DIAGRAM 27.3 Page 03 of 11 G00403-01...
  • Page 209 WIRING DIAGRAM Components: Low beam, high beam Fuse Fuse Combination instrument Horn Parking light Light switch, horn button, headlight flasher switch, turn signal switch...

  • Page 210: 208

    WIRING DIAGRAM 27.4 Page 04 of 11 G00404-01...
  • Page 211 WIRING DIAGRAM Components: Front brake light switch Rear brake light switch License plate lamp Brake/tail light...

  • Page 212: 210

    WIRING DIAGRAM 27.5 Page 05 of 11 G00405-01...
  • Page 213 WIRING DIAGRAM Components: Turn signal relay Combination instrument Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right Light switch, horn button, headlight flasher switch, turn signal switch...

  • Page 214: 212

    WIRING DIAGRAM 27.6 Page 06 of 11 G00406-01...
  • Page 215 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 216: 214

    WIRING DIAGRAM 27.7 Page 07 of 11 bl-ye gn-or gn-or bu-gn bu-gn wh-or wh-or ye-or ye-or bl-pk bl-pk bu-pk bu-pk bu-pk bl-pk gn-pk gn-pk pu-gn pu-gn bl-pu bl-pu bu-pu bu-pu wh-pu wh-pu ye-pu ye-pu bl-or bl-or bl-gr bl-gr G00407-01...
  • Page 217 WIRING DIAGRAM Components: EFI control unit Accelerator position sensor Fuse Fuel evaporation valve Injector cylinder 1 Motor drive R51/1 Ignition coil 1, (cylinder 1) R51/2 Ignition coil 2, (cylinder 1)

  • Page 218: 216

    WIRING DIAGRAM 27.8 Page 08 of 11 G00408-01...
  • Page 219 WIRING DIAGRAM Components: EFI control unit Intake air temperature sensor Engine coolant temperature sensor cylinder 1 Oil pressure sensor Clutch switch Lambda sensor (cylinder 1) Combination instrument Switch Map‑Select Switch...

  • Page 220: 218

    WIRING DIAGRAM 27.9 Page 09 of 11 G00409-01...
  • Page 221 WIRING DIAGRAM Components: EFI control unit Ambient air pressure sensor Rollover sensor Side stand switch Accelerator position sensor Manifold absolute pressure sensor cylinder 1 Combination instrument...

  • Page 222: 220

    WIRING DIAGRAM 27.10 Page 10 of 11 G00410-01...
  • Page 223 WIRING DIAGRAM Components: EFI control unit Fuel level indicator Crankshaft position sensor Combination instrument...

  • Page 224: 222

    WIRING DIAGRAM 27.11 Page 11 of 11 G00411-01...
  • Page 225 WIRING DIAGRAM Components: EFI control unit ABS control unit Front wheel speed sensor Wheel speed sensor, rear Fuse ABS fuse ABS fuse Combination instrument X295 Diagnostics connector Cable colors: Black Brown Blue Green Gray light blue Orange pink Violet White Yellow...

  • Page 226: Substances

    241) – SAE ( p. 241) (SAE 10W/60) – KTM LC4 2007+ Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre- sponding properties. Synthetic engine oil...
  • Page 227 SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 241) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Hydraulic fluid (15) Standard/classification –...

  • Page 228: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Recommended supplier Motorex ® – Chain Clean Chain lube for road use Guideline Recommended supplier Motorex ® – Chainlube Road Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Long-life grease Recommended supplier Motorex ® – Bike Grease 2000 Lubricant (T511) Recommended supplier...
  • Page 229 AUXILIARY SUBSTANCES Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ® – Quick Cleaner Universal oil spray Recommended supplier Motorex ®...

  • Page 230: 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 231 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 232 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 233 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 234 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 235 SPECIAL TOOLS Mounting tool for lock ring Art. no.: 75029005000 305660-10 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...
  • Page 236 SPECIAL TOOLS 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 Upper part, pressing-out tool Art. no.: 75029047050 400186-01...
  • Page 237 SPECIAL TOOLS 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 Floor jack attachment Art. no.: 75029055000 400184-01...
  • Page 238 SPECIAL TOOLS 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 Spark plug wrench Art. no.: 75029172000 400170-01...
  • Page 239 SPECIAL TOOLS 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 Pin wrench Art. no.: T103 200734-10...
  • Page 240 SPECIAL TOOLS Hook wrench Art. no.: T106S 301085-01 Depth micrometer Art. no.: T107S 300577-10 Art. no.: T120 201235-10 Pressing tool Art. no.: T1206 200583-10 Pressing tool Art. no.: T1207S 200585-01...
  • Page 241 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 Open-end wrench Art. no.: T14032 200640-10...
  • Page 242 SPECIAL TOOLS Clamping stand Art. no.: T1403S 200637-10 Mounting tool Art. no.: T14040S 200634-10 Mounting sleeve Art. no.: T1515 300569-10 Nitrogen filling tool Art. no.: T170S1 300574-10...

  • Page 243: 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 244: Index

    INDEX front brake, removing ......74 INDEX rear brake, installing ......76 Accessories .
  • Page 245 INDEX clutch basket, removing ..... . 119 piston ring end gap, checking ....134 clutch cover, removing .
  • Page 246 INDEX Front wheel Oil filter fitting ........73 changing .
  • Page 247 INDEX Spark plug connector checking ....... . 187 Spoke tension checking .
  • Page 248 *3206193en* 3206193en 03/2014 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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