KTM 690 ENDURO R Owner's Manual
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KTM 690 ENDURO R Owner's Manual

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OWNER'S MANUAL
2016
690 Enduro R
Art. no. 3213395en

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Summary of Contents for KTM 690 ENDURO R

  • Page 1 OWNER'S MANUAL 2016 690 Enduro R Art. no. 3213395en...
  • Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.
  • Page 4 Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Shock absorber article number ......22 TABLE OF CONTENTS MEANS OF REPRESENTATION ........7 CONTROLS..............23 Symbols used ............7 Clutch lever............23 Formats used............8 Hand brake lever..........23 SAFETY ADVICE.............. 9 Throttle grip ............24 Use definition - intended use ........
  • Page 6 TABLE OF CONTENTS 6.13 Seat release ............38 10.6 Adjusting the high-speed compression damping of the shock absorber ......... 65 6.14 Handrails ............38 10.7 Adjusting the rebound damping of the shock 6.15 Passenger footrests ..........39 absorber............66 6.16 Shift lever ............
  • Page 7 TABLE OF CONTENTS 11.16 Checking the chain, rear sprocket, engine 13.6 Checking the tire condition ....... 121 sprocket, and chain guide ........87 13.7 Checking the tire air pressure......123 11.17 Adjusting chain guide ........92 13.8 Checking the spoke tension....... 124 11.18 Adjusting basic position of clutch lever ....
  • Page 8 TABLE OF CONTENTS 17 SERVICE WORK ON THE ENGINE ........ 156 22.7 Fork..............188 17.1 Checking the engine oil level......156 22.8 Shock absorber ..........189 17.2 Changing the engine oil and filter, cleaning the 22.9 Chassis tightening torques ........ 190 oil screens ...........

  • Page 9: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required.

  • Page 10: Formats Used

    MEANS OF REPRESENTATION Formats used The typographical formats used in this document are explained below. Specific name Identifies a proprietary name. Name ® Identifies a protected name. Brand™ Identifies a brand available on the open market. Underlined terms Refer to technical details of the vehicle or indicate technical terms that are explained in the glossary.

  • Page 11: Safety Advice

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

  • Page 12: Degrees Of Risk And Symbols

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

  • Page 13: Safe Operation

    Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. An appropriate driver's license is needed to ride the vehicle on public roads. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.

  • Page 14: Protective Clothing

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

  • Page 15: Owner's Manual

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

  • Page 16: Important Notes

    Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the warranty.

  • Page 17: Service

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

  • Page 18: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left side (example) B01940-10...
  • Page 19 VIEW OF VEHICLE Hand brake lever ( p. 23) Clutch lever ( p. 23) Handrails ( p. 38) Filler cap Engine number ( p. 21) Shift lever ( p. 39) Side stand ( p. 41) Seat release ( p. 38) Passenger footrests ( p.

  • Page 20: View Of Vehicle, Rear Right Side (Example)

    VIEW OF VEHICLE View of vehicle, rear right side (example) B01941-10...
  • Page 21 VIEW OF VEHICLE Light switch ( p. 25) Turn signal switch ( p. 25) Horn button ( p. 24) Ignition/steering lock ( p. 27) Function buttons ( p. 28) Indicator lamps ( p. 29) Emergency OFF switch ( p. 26) Electric starter button ( p.

  • Page 22: 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. H01049-10...

  • Page 23: Key Number

    SERIAL NUMBERS Key number  can be found on the KEYCODECARD. The key number Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place. 402241-10 Engine number  The engine number is stamped on the left side of the engine under the engine sprocket. 401949-10...

  • Page 24: Fork Part Number

    SERIAL NUMBERS Fork part number  The fork part number is stamped on the inner side of the fork stub. 401947-10 Shock absorber article number  The shock absorber article number is on the left side of the shock absorber. 402025-10...

  • Page 25: Controls

    CONTROLS Clutch lever  The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. B01943-10 Hand brake lever  The hand break lever is fitted on the right side of the handlebar. The hand brake lever operates the front brake.

  • Page 26: Throttle Grip

    CONTROLS Throttle grip  The throttle grip is fitted on the right side of the handlebar. B01945-10 Horn button  The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed –...

  • Page 27: Light Switch

    CONTROLS Light switch  The light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is turned downward. In this position, the low beam and tail light are switched on. High beam on – Light switch is turned upward. In this position, the high beam and tail light are switched on.

  • Page 28: Emergency Off Switch

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

  • Page 29: Ignition/Steering Lock

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

  • Page 30: Function Buttons

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

  • Page 31: Indicator Lamps

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

  • Page 32: Display

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

  • Page 33: Speed Display

    CONTROLS 6.10.6 Speed display  The speed is shown in kilometers per hour km/h or in miles per hour mph. 400838-10 6.10.7 Setting the kilometers or miles Info If the unit is changed, the value is retained and converted accordingly. Make the setting according to the country.

  • Page 34: Time

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

  • Page 35: 6.10.10 Odo Display

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

  • Page 36: Setting/Resetting Display Trip 2

    CONTROLS – Switch on the ignition by turning the ignition key to position ON – Press the MODE button repeatedly until the TRIP 1 mode is active. – Keep the SET button pressed. The TRIP 1 display is set to 0.0. 401445-01 6.10.12 Setting/resetting display TRIP 2 Info...

  • Page 37: 6.10.13 Trip F Display

    CONTROLS 6.10.13 TRIP F display If the fuel level drops to the reserve mark, the display automatically changes to TRIP F and starts to count from 0.0, regardless of the previous display mode. Info The low fuel warning lamp lights up in parallel to the TRIP F display. 401447-01 6.10.14 GEAr display In display mode GEAr, the gear currently engaged is displayed.

  • Page 38: 6.10.15 Coolant Temperature Indicator

    CONTROLS 6.10.15 Coolant temperature indicator The temperature display consists of 12 bars. The more bars that light up, the hotter the coolant. When the upper bar lights up, all bars in the display begin to flash and the temper- ature warning lamp lights up. Possible states Engine cold –...

  • Page 39: Closing Filler Cap

    CONTROLS Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. –  Lift cover of filler cap and insert the ignition key. –...

  • Page 40: Seat Release

    CONTROLS 6.13 Seat release  The seat can be released using strap B01948-10 6.14 Handrails  The handrails are used for moving the motorcycle around. When you have a passenger, the passenger can hold on the handrails during the journey. 601773-10...

  • Page 41: Passenger Footrests

    CONTROLS 6.15 Passenger footrests The passenger footrests can be folded up and down. Possible states Passenger footrests folded up – For operation without a passenger. • Passenger footrests folded down – For operation with a passenger. • 601774-01 6.16 Shift lever ...

  • Page 42: Foot Brake Lever

    CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.17 Foot brake lever  Foot brake lever is located in front of the right footrest. The rear brake is engaged with the foot brake lever. 401956-10...

  • Page 43: Side Stand

    CONTROLS 6.18 Side stand  The side stand is located on the left side of the vehicle. The side stand is used for parking the motorcycle. Info The side stand must be folded up during motorcycle use. The side stand is coupled with the safety starting system – see the riding instruc- tions.

  • Page 44: Preparing For Use

    The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning Danger of accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels. – Only tires/wheels approved by KTM and with the corresponding speed index should be used. Warning Danger of accidents Reduced road grip with new tires. –...

  • Page 45: Running In The Engine

    When using your vehicle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.

  • Page 46: Loading The Vehicle

    PREPARING FOR USE Guideline Maximum engine speed During the first: 1,000 km (620 mi) 6,000 rpm After the first: 1,000 km (620 mi) 7,800 rpm – Avoid fully opening the throttle! Loading the vehicle Warning Danger of accidents Unstable handling characteristics. –...
  • Page 47 PREPARING FOR USE Warning Danger of accidents Poor visibility for other road users due to slipped baggage. – If the tail light is covered, you are less visible to traffic behind you, especially when it is dark. Check that your baggage is fixed properly at regular intervals.

  • Page 48: Riding Instructions

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

  • Page 49: Starting

    RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
  • Page 50 Take the weight off the side stand and swing it back up with your foot as far as it will Switching off ABS KTM recommends riding with ABS at all times. However, situations may arise in which ABS is not advantageous.

  • Page 51: Starting Off

    RIDING INSTRUCTIONS Starting off – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully. Shifting, riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control. –...
  • Page 52 RIDING INSTRUCTIONS Warning Danger of accidents Reduced road grip with cold tires. – On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured. Warning Danger of accidents Reduced road grip with new tires. –...
  • Page 53 Info If unusual noises arise during operation, stop immediately, switch off the engine, park the vehicle properly, and contact an autho- rized KTM workshop. – Shift into a higher gear when conditions allow (incline, road situation, etc.). –...

  • Page 54: Applying The Brakes

    Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. – Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Failure of brake system.
  • Page 55 RIDING INSTRUCTIONS Warning Danger of accidents Longer stopping distance due to higher overall weight. – Take the longer stopping distance into account when carrying a passenger and baggage. Warning Danger of accidents Delayed brake action on salted roads. – There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the deposits from the discs by carefully applying the brakes.

  • Page 56: Stopping, Parking

    RIDING INSTRUCTIONS Warning Danger of accidents Road grip is reduced when braking with the motorcycle at an angle or on a laterally inclined surface. – Braking should be completed before you enter into a bend. – Always finish braking before you go into a bend. Change down to a lower gear appropriate to your road speed. –...

  • Page 57: Transport

    RIDING INSTRUCTIONS Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run.

  • Page 58: Refueling

    RIDING INSTRUCTIONS Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run.
  • Page 59 – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards.
  • Page 60 RIDING INSTRUCTIONS – Press the SET button  for two seconds.  The fuel level warning lamp switches off. TRIP F is set to 0.0 and the display returns to the previous display mode. Info  If you do not press the SET button , the reset takes place automatically after approx.

  • Page 61: Service Schedule

    ○ ● ● Check that the electrical equipment is functioning correctly. ○ ● ● Read out the fault memory using the KTM diagnostics tool. ● ● Check the measured service values with the KTM diagnostics tool. ○ ● ● Change the engine oil and filter, clean the oil screens.
  • Page 62 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 the KTM Dealer.net and in the Service and Warranty Booklet.
  • Page 63 SERVICE SCHEDULE ○ One-time interval ● Periodic interval...

  • Page 64: Tuning The Chassis

    TUNING THE CHASSIS 10.1 Fork/shock absorber The fork and the shock absorber offer many options of adapting the chassis to your riding style and the payload. Info  To help you adapt the vehicle, we have summarized our findings in Table .

  • Page 65: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS Guideline Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 10.3 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork rebound behavior. –...

  • Page 66: Compression Damping Of The Shock Absorber

    Adjusting the low-speed compression damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)

  • Page 67: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    Adjusting the high-speed compression damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)

  • Page 68: Adjusting The Rebound Damping Of The Shock Absorber

    Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)

  • Page 69: Measuring The Unloaded Rear Wheel Sag

    TUNING THE CHASSIS – Turn adjusting screw  clockwise up to the last perceptible click. – Turn counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks 100247-10 Full payload 10 clicks...

  • Page 70: Checking The Static Sag Of The Shock Absorber

    TUNING THE CHASSIS Finishing work – Remove the motorcycle from the lift stand. ( p. 74) 10.9 Checking the static sag of the shock absorber –  Measure distance of rear wheel unloaded. ( p. 67) – Hold the motorcycle upright with the aid of an assistant. –...

  • Page 71: Checking The Riding Sag Of The Shock Absorber

    Adjusting the spring preload of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)
  • Page 72 TUNING THE CHASSIS Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. Preparatory work – Raise the motorcycle with the work stand. – Remove the seat. ( p. 80) –...

  • Page 73: Adjusting The Riding Sag

    TUNING THE CHASSIS – Mount the seat. ( p. 80) – Remove the motorcycle from the work stand. 10.12 Adjusting the riding sag Preparatory work – Raise the motorcycle with the work stand. – Remove the seat. ( p. 80) –...

  • Page 74: Handlebar Position

    TUNING THE CHASSIS 10.13 Handlebar position  On the upper triple clamp, there are two holes at a distance of to each other. 15 mm (0.59 in)  Hole distance  The holes on the handlebar support are placed at a distance of from the center.
  • Page 75 TUNING THE CHASSIS – Position the handlebar. Info Make sure the cables and wiring are positioned correctly. – Position the handlebar clamps. Mount screws  and tighten evenly. Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft)

  • Page 76: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Use the underride guard underneath the engine to raise the vehicle. Lift stand (78929955100) Neither wheel is in contact with the ground.

  • Page 77: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS – Remove the motorcycle from the lift stand and rest it on side stand  – Remove the lift stand. 401943-10 11.3 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p.

  • Page 78: Loosening The Fork Protection

    SERVICE WORK ON THE CHASSIS – Clean and oil the dust boots and inner fork tube of both fork legs. Universal oil spray ( p. 199) – Press the dust boots back into their normal position. – Remove excess oil. Finishing work –...

  • Page 79: Positioning The Fork Protector

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

  • Page 80: Adjusting The Play Of The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable on the steering head bearing. » If there is detectable play: –...
  • Page 81 SERVICE WORK ON THE CHASSIS Main work –   Loosen screw . 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 82: Removing The Seat

    SERVICE WORK ON THE CHASSIS 11.8 Removing the seat –  Pull on strap and raise the rear of the seat at the same time. – Pull back the seat and lift it off. B01948-10 11.9 Mounting the seat M00648-10 –...

  • Page 83: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 11.10 Removing the air filter Preparatory work – Remove the seat. ( p. 80) Main work –   Remove screws . Take off air filter box top 601783-10 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine.

  • Page 84: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 11.11 Installing the air filter Main work – Clean the air filter box. –  Mount air filter Info The air filter must lie flush against the air filter box along the entire sealing sur- face ...

  • Page 85: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS 11.12 Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 83) 400678-01 11.13 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. –...

  • Page 86: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS Info The service life of the chain depends largely on its maintenance. Preparatory work – Raise the motorcycle with a lift stand. ( p. 74) Main work – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. –...
  • Page 87 SERVICE WORK ON THE CHASSIS – Lean the motorcycle on the side stand. – Shift gear to neutral. –  Push the chain upward at a distance from the chain sliding guard and determine  the chain tension Info  The upper chain section must be taut.

  • Page 88: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 11.15 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, bearings in the transmission and in the rear wheel) will be under additional load.

  • Page 89: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 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 adjusting screws on the left and right so that the markings on the left and ...
  • Page 90 SERVICE WORK ON THE CHASSIS Main work – Shift the transmission to idle. – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket or engine sprocket is worn: – Change the power set. Info The engine sprocket, rear sprocket, and chain should always be replaced together.
  • Page 91 SERVICE WORK ON THE CHASSIS Info When the chain is replaced, the rear sprocket and engine sprocket should also be changed. New chains wear out faster on an old, worn rear sprocket or engine sprocket. – Check the chain sliding guard for wear. »...

  • Page 92: Nm (12.5 Lbf Ft)

    SERVICE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated. »...
  • Page 93 SERVICE WORK ON THE CHASSIS – Check that the chain guide is firmly seated. » If the chain guide is loose: – Tighten the screws on the chain guide. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 101068-01 Finishing work –...

  • Page 94: Adjusting Chain Guide

    SERVICE WORK ON THE CHASSIS 11.17 Adjusting chain guide –   Remove screws . Take off the chain guide. Condition Number of teeth: ≤ 44 teeth –   Insert nut in hole . Position the chain guide. – ...

  • Page 95: Adjusting Basic Position Of Clutch Lever

    SERVICE WORK ON THE CHASSIS 11.18 Adjusting basic position of clutch lever Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar. The range of adjustment is limited.

  • Page 96: Removing The Engine Guard

    SERVICE WORK ON THE CHASSIS – Remove screws  –   Remove cover with membrane – Check the fluid level. Fluid level under top level of container 4 mm (0.16 in) » If the level of the coolant does not meet specifications: –...

  • Page 97: Installing The Engine Guard

    SERVICE WORK ON THE CHASSIS 11.21 Installing the engine guard –  Slide the engine guard into holders at the rear. –  Position the engine guard. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) G00755-10...

  • Page 98: Brake System

    KTM. – Service work and repairs must be performed properly. (Your authorized KTM workshop will be glad to help.) The ABS is a safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces.

  • Page 99: Adjusting The Basic Position Of The Hand Brake Lever

    BRAKE SYSTEM the brake pressure. The regulating process causes a slight pulsing of the hand and foot brake levers.  ABS warning lamp must light up after the ignition is switched on and go out after start- ing off. If it does not go out after starting off or if it lights up while riding, this indicates a fault in the ABS system.

  • Page 100: Checking The Brake Discs

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

  • Page 101: Checking Brake Fluid Level Of Front Brake

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

  • Page 102: Topping Up Brake Fluid Of Front Brake

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

  • Page 103: Checking The Front Brake Linings

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

  • Page 104: Changing The Front Brake Linings

    If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)
  • Page 105 Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin- ings.
  • Page 106 BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. –  Remove screws –   Remove cover with membrane – Press the brake caliper by hand onto the brake disc in order to retract the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does.

  • Page 107: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM – Check that leaf spring  in the brake caliper and sliding plate  in the brake caliper support are seated correctly. – Insert the new brake linings, insert the pin, and mount the cotter pin. Info Always change the brake linings in pairs. –...

  • Page 108: Adjusting The Basic Position Of The Foot Brake Lever

    BRAKE SYSTEM – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel  Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) Info You will know that contact has been made with the foot brake cylinder piston when there is increased resistance when you activate the foot brake lever.

  • Page 109: Checking Rear Brake Fluid Level

    If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

  • Page 110: Adding Rear Brake Fluid

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.
  • Page 111 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 112: Checking The Rear Brake Linings

    – Change the rear brake linings. p. 110) B01962-01 12.13 Changing the rear brake linings Warning Danger of accident Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.)
  • Page 113 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
  • Page 114 BRAKE SYSTEM Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.
  • Page 115 BRAKE SYSTEM – Check that leaf spring  in the brake caliper and sliding plate  in the brake caliper support are seated correctly. – Insert the new brake linings, insert the pin, and mount the cotter pin. Info Always change the brake linings in pairs. –...

  • Page 116: Wheels, Tires

    WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 74) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pis- tons.

  • Page 117: Installing The Front Wheel

    WHEELS, TIRES Warning Danger of accidents Reduced braking efficiency due to damaged brake disc. – Always lay the wheel down in such a way that the brake disc is not damaged. – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork.
  • Page 118 WHEELS, TIRES – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Replace the wheel bearing. –   Clean and grease shaft seal rings and contact surface of the spacers. Long-life grease ( p.

  • Page 119: Removing The Rear Wheel

    WHEELS, TIRES Guideline Screw, wheel speed sensor 6 Nm (4.4 lbf ft) 13.3 Removing the rear wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 74) Main work – Remove screw  and pull wheel speed sensor ...

  • Page 120: Installing The Rear Wheel

    WHEELS, TIRES – Push the rear wheel forward as far as possible and take the chain off the rear sprocket. Warning Danger of accidents Reduced braking efficiency due to damaged brake disc. – Always lay the wheel down in such a way that the brake disc is not damaged. –...
  • Page 121 WHEELS, TIRES – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Replace the wheel bearing. –   Clean and grease the shaft seal rings and mating surfaces of the spacers. Long-life grease ( p.

  • Page 122: Checking The Rear Hub Rubber Dampers

    WHEELS, TIRES Guideline Screw, wheel speed sensor 6 Nm (4.4 lbf ft) – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. Finishing work – Remove the motorcycle from the lift stand. ( p.

  • Page 123: Checking The Tire Condition

    Danger of accidents Uncontrollable vehicle handling in the event of a flat tire. – In the interest of safety, replace damaged or worn tires immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
  • Page 124 WHEELS, TIRES 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. – New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be rough- ened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles.

  • Page 125: Checking The Tire Air Pressure

    DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture. KTM recommends that the tires are changed regardless of the actual wear, at the latest after 5 years.

  • Page 126: Checking The Spoke Tension

    Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes.

  • Page 127: Electrical System

    ELECTRICAL SYSTEM 14.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...
  • Page 128 ELECTRICAL SYSTEM – Disconnect negative cable  of the battery. –  Take off the positive pole cover S00622-10 –   Disconnect the ABS connection cable and positive cable from the battery. S00620-10 –  Remove screws –  Pull retaining bracket of the battery forward and remove it.

  • Page 129: Installing The Battery

    ELECTRICAL SYSTEM 14.2 Installing the battery Main work – Insert the battery into the battery compartment with the terminals facing rearward. Battery (YTZ10S) ( p. 187) –   Position retaining bracket and mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) S00621-11 –...
  • Page 130 ELECTRICAL SYSTEM – Position positive terminal cover  –   Position washer and negative cable , and mount and tighten the screw. Guideline Screw, battery terminal 4.5 Nm (3.32 lbf ft) S00622-11 –  Position the engine electronics control unit –...

  • Page 131: Recharging The Battery

    – Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly 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 132 ELECTRICAL SYSTEM Info Even when there is no load on the battery, it still loses power steadily. The charging level and the method of charging are very important for the service life of the battery. Rapid recharging with a high charging current shortens the battery's service life. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves.
  • Page 133 ELECTRICAL SYSTEM Main work – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the bat- tery, and to test the alternator. With this device, you cannot overcharge the battery. Info ...

  • Page 134: Changing The Main Fuse

    ELECTRICAL SYSTEM 14.4 Changing the main fuse Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass 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 135: Changing The Abs Fuses

    ELECTRICAL SYSTEM – 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. – Install a new main fuse. Fuse (58011109130) ( p.
  • Page 136 ELECTRICAL SYSTEM Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. ( p. 80) – Remove the battery cover. – Pull the EFI control unit off of the holder and set it to one side. To change the fuse of the ABS hydraulic unit: –...

  • Page 137: Changing Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM 14.6 Changing fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. ( p.
  • Page 138 ELECTRICAL SYSTEM 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 Fuse 7 - 10 A - for auxiliary equipment (permanent positive)

  • Page 139: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM Put a new spare fuse in the fuse box for future use if needed. – Check the function of power consumers. – Close the fuse box cover. Finishing work – Mount the seat. ( p. 80) 14.7 Removing the headlight mask with the headlight Preparatory work –...

  • Page 140: Installing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM – Disconnect plug-in connector  of the turn signals and  of the headlight. – Remove the headlight mask. 601794-10 14.8 Installing the headlight mask with the headlight Main work –   Connect plug-in connectors of the headlight and of the turn signals.

  • Page 141: Changing The Headlight Bulb

    ELECTRICAL SYSTEM – Remove the cloth from the fender and position the headlight mask.  Holding lugs reach into the headlight mask. 601810-10 –   Position line guides . Mount and tighten screws Guideline Screw, headlight mask 5 Nm (3.7 lbf ft) B01982-11 Finishing work –...
  • Page 142 ELECTRICAL SYSTEM Preparatory work – Switch off all power consumers and switch off the engine. – Remove the headlight mask with the headlight. ( p. 137) Main work –  Pull off connector –  Take off protection cap of the headlight bulb. 600610-10 –...

  • Page 143: Changing The Parking Light Bulb

    ELECTRICAL SYSTEM 14.10 Changing the parking light bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.

  • Page 144: Changing The Turn Signal Bulb

    ELECTRICAL SYSTEM – Pull bulb socket  out of the reflector. –  Pull parking light bulb out of the bulb socket. – Insert a new parking light bulb in the bulb socket. Parking light (W5W / socket W2.1x9.5d) ( p.
  • Page 145 ELECTRICAL SYSTEM Main work – Remove the screw on the rear of the turn signal housing. –  Tilt headlamp diffuser forward carefully and take it off. –  Lightly squeeze the orange plug in the area of the holding lugs and take it off. –...

  • Page 146: Checking The Headlight Setting

    ELECTRICAL SYSTEM 14.12 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 147 ELECTRICAL SYSTEM Main work –  Turn adjusting screw to adjust the headlight range. Guideline The boundary between light and dark must be exactly on the lower mark for a motor- cycle with a rider (instructions on how to apply the mark: Checking the headlight set- ting).

  • Page 148: Cooling System

    COOLING SYSTEM 15.1 Cooling system  The water pump in the engine forces the coolant to flow. The pressure in the cooling system resulting from heat is regulated by a valve in the radia-  tor cap . The heat expansion causes the surplus coolant to flow into the compensating tank ...
  • Page 149 COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immedi- ately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, con- tact a physician immediately.

  • Page 150: Checking The Coolant Level

    COOLING SYSTEM – Screw off the radiator cap  – Check antifreeze of coolant. −25… −45 °C (−13… −49 °F) » If the antifreeze of the coolant does not meet specifications: – Correct the antifreeze of the coolant. – Check the coolant level in the radiator. The radiator must be completely filled.

  • Page 151: Draining The Coolant

    COOLING SYSTEM Condition Engine is cold. – Stand the motorcycle on its side stand on a horizontal surface. –  Check the coolant level in the compensating tank The coolant level must be within the range shown in the figure. »...

  • Page 152: Filling/Bleeding The Cooling System

    COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immedi- ately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, con- tact a physician immediately.
  • Page 153 COOLING SYSTEM – Stand the motorcycle on its side stand on a horizontal surface. –  Remove radiator cap 601799-11 – Refill the coolant. Coolant ( p. 195) –  Fill the radiator completely with coolant. Mount radiator cap 601800-10 –...
  • Page 154 COOLING SYSTEM Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 155: Tuning The Engine

    TUNING THE ENGINE 16.1 Adjusting the engine characteristic Preparatory work – Switch off the ignition by turning the ignition key to position OFF – Remove the seat. ( p. 80) Main work –  Pull the Map‑Select switch and holder upward off of the retaining bracket.

  • Page 156: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE – Position the Map‑Select switch in the holder. – Slide the Map‑Select switch with the holder downward onto the retaining bracket. Finishing work – Mount the seat. ( p. 80) 16.2 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position.

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

    TUNING THE ENGINE 16.3 Adjusting the basic position of the shift lever –   Remove screw with washers and take off shift lever 401950-12 –  Clean gear teeth of the shift lever and shift shaft. –  Mount shift lever on the shift shaft in the required position and engage the gearing.

  • Page 158: Service Work On The Engine

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

  • Page 159: Changing The Engine Oil And Filter, Cleaning The Oil Screens

    SERVICE WORK ON THE ENGINE 17.2 Changing the engine oil and filter, cleaning the oil screens – Drain the engine oil. p. 157) – Remove the oil filter. p. 158) – Clean the oil screens. p. 160) – Install the oil filter. p.

  • Page 160: Removing The Oil Filter

    SERVICE WORK ON THE ENGINE Main work – Place a suitable container under the engine. –  Remove oil drain plug with the magnet and seal ring. – Completely drain the engine oil. 100200-10 – Thoroughly clean the oil drain plug with magnet. –...
  • Page 161 SERVICE WORK ON THE ENGINE Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Preparatory work – Place a suitable container under the engine. Main work –...

  • Page 162: Cleaning The Oil Screens

    SERVICE WORK ON THE ENGINE 17.5 Cleaning the oil screens Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 163 SERVICE WORK ON THE ENGINE – Remove screw plug  with oil screen  and the O-rings. – Completely drain the engine oil. – Thoroughly clean the parts and sealing area. 100206-10 –  Position oil screen with the O-rings. –...

  • Page 164: Installing The Oil Filter

    SERVICE WORK ON THE ENGINE 17.6 Installing the oil filter –   Insert oil filters –   Oil the O-rings of the oil filter covers. Mount oil filter covers – Mount and tighten the screws. Guideline Screw, oil filter cover M5x16 6 Nm (4.4 lbf ft) B01984-10...

  • Page 165: Adding Engine Oil

    SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
  • Page 166 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 167: Cleaning, Care

    CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pres- sure can cause malfunctions or destroy these parts.
  • Page 168 CLEANING, CARE – After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly. – Remove the plug from the exhaust system. Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake sys- tem.

  • Page 169: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE Special cleaner for glossy and matte paint finishes, metal and plastic surfaces p. 199) – Lubricate the ignition/steering lock. Universal oil spray ( p. 199) 18.2 Checks and maintenance steps for winter operation Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt.
  • Page 170 CLEANING, CARE – Clean the chain. ( p. 83)

  • Page 171: Storage

    0… 35 °C (32… 95 °F) direct sunshine – Store the vehicle in a dry location that is not subject to large fluctuations in tempera- ture. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with a lift stand. ( p. 74)

  • Page 172: Preparing For Use After Storage

    STORAGE – Cover the motorcycle with a tarp or similar cover that is permeable to air. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust.

  • Page 173: Troubleshooting

    Connect the plug-in connection of the fuel line. connection is not connected – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Throttle opened while starting When starting, DO NOT open the throttle –...
  • Page 174 Fill/bleed the cooling system. p. 150) – FI warning lamp (MIL) lights/flashes Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – N The idling speed indicator lamp does Gear position sensor not programmed...
  • Page 175 TROUBLESHOOTING Faults Possible cause Action – High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary. – Engine oil level too high Check the engine oil level. ( p. 156) – Engine oil too thin (low viscosity) Change the engine oil and filter, clean the oil screens.

  • Page 176: Blink Code

    BLINK CODE Blink code FI of warning lamp (MIL) 02 FI warning lamp (MIL) flashes briefly 2x Error level condition Crankshaft position sensor - circuit fault Blink code FI of warning lamp (MIL) 09 FI warning lamp (MIL) flashes briefly 9x Error level condition Manifold absolute pressure sensor cylinder 1 - input signal too low Manifold absolute pressure sensor cylinder 1 - input signal too high...
  • Page 177 BLINK CODE Blink code FI of warning lamp (MIL) 15 FI warning lamp (MIL) flashes 1x long, 5x short Error level condition Rollover sensor - input signal too low Rollover sensor - input signal too high Blink code FI of warning lamp (MIL) 17 FI warning lamp (MIL) flashes 1x long, 7x short Error level condition...
  • Page 178 BLINK CODE Blink code FI of warning lamp (MIL) 27 FI warning lamp (MIL) flashes 2x long, 7x short Error level condition Accelerator position sensor circuit fault - accelerator position sensor voltage Blink code FI of warning lamp (MIL) 33 FI warning lamp (MIL) flashes 3x long, 3x short Error level condition Injector cylinder 1 - circuit fault Blink code FI of warning lamp...
  • Page 179 BLINK CODE Blink code FI of warning lamp (MIL) 45 FI warning lamp (MIL) flashes 4x long, 5x short Error level condition Lambda sensor heater cylinder 1, sensor 1 - short circuit to ground or open circuit Lambda sensor heater cylinder 1, sensor 1 - input signal too high Blink code FI of warning lamp (MIL) 65 FI warning lamp (MIL) flashes 6x long, 5x short...
  • Page 180 BLINK CODE Blink code FI of warning lamp (MIL) 85 FI warning lamp (MIL) flashes 8x long, 5x short Error level condition Accelerator position sensor circuit A - input signal too low Accelerator position sensor circuit A - input signal too high Blink code FI of warning lamp (MIL) 86 FI warning lamp (MIL) flashes 8x long, 6x short...
  • Page 181 BLINK CODE Blink code FI of warning lamp (MIL) 92 FI warning lamp (MIL) flashes 9x long, 2x short Error level condition DBW throttle actuator control IC - stuck open Blink code FI of warning lamp (MIL) 93 FI warning lamp (MIL) flashes 9x long, 3x short Error level condition CPU mutual - surveillance error Blink code FI of warning lamp...

  • Page 182: Technical Data

    TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 690 cm³ (42.11 cu in) Stroke 84.5 mm (3.327 in) Bore 102 mm (4.02 in) Compression ratio 12.6:1 Idle speed Coolant temperature: ≥ 70 °C (≥ 158 °F) 1,550… 1,650 rpm Control OHC, 4 valves controlled via rocker arm, chain drive Valve diameter, intake...

  • Page 183: Engine Tightening Torques

    TECHNICAL DATA 3rd gear 21:28 4th gear 21:23 5th gear 23:22 6th gear 23:20 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 224 W Spark plug Inside spark plug NGK LKAR8BI-9 Outside spark plug NGK LMAR7A-9 Spark plug electrode gap...
  • Page 184 TECHNICAL DATA Screw, gear position sensor M5x16 5 Nm (3.7 lbf ft) Loctite ® 243™ – Screw, oil filter cover M5x16 6 Nm (4.4 lbf ft) Screw, oil pump cover, top 6 Nm (4.4 lbf ft) Loctite ® 243™ Loctite ®...
  • Page 185 TECHNICAL DATA Screw, thermostat case M6x20 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, timing chain guide rail M6x30 10 Nm (7.4 lbf ft) Loctite ® 2701™ Screw, timing chain tensioning rail M6x30 10 Nm (7.4 lbf ft) Loctite ®...

  • Page 186: Capacities

    TECHNICAL DATA – Screw, unlocking of timing chain ten- M10x1 10 Nm (7.4 lbf ft) sioner – Spark plug outside M10x1 11 Nm (8.1 lbf ft) – Spark plug inside M12x1.25 18 Nm (13.3 lbf ft) – Coolant temperature sensor on cylinder M12x1.5 12 Nm (8.9 lbf ft) head...

  • Page 187: Coolant

    TECHNICAL DATA 22.3.2 Coolant Coolant 1.20 l (1.27 qt.) Coolant ( p. 195) 22.3.3 Fuel Total fuel tank capacity, approx. 12 l (3.2 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 197) Fuel reserve, approx. 2.5 l (2.6 qt.) 22.4 Chassis Frame...
  • Page 188 TECHNICAL DATA Rear 4.5 mm (0.177 in) Tire air pressure, road, solo Front 1.8 bar (26 psi) Rear 1.8 bar (26 psi) Tire air pressure with passenger / fully loaded Front 2.2 bar (32 psi) Rear 2.2 bar (32 psi) Tire air pressure, offroad, single rider Front 1.5 bar (22 psi)

  • Page 189: Electrical System

    TECHNICAL DATA 22.5 Electrical system Battery YTZ10S Battery voltage: 12 V Nominal capacity: 8.6 Ah maintenance-free Fuse 58011109115 15 A Fuse 58011109125 25 A Fuse 58011109130 30 A Fuse 75011088015 15 A Fuse 75011088010 10 A Headlight H4 / socket P43t 12 V 60/55 W Parking light...

  • Page 190: Tires

    Rear tires 90/90 - 21 M/C 54S TL 140/80 - 18 M/C 70S TL Metzeler Enduro 3 Sahara Metzeler Enduro 3 Sahara Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork Fork part number 14.18.8N.10 Fork WP Performance Systems 4860 MXTA SPLIT...

  • Page 191: Shock Absorber

    TECHNICAL DATA Fork length 895 mm (35.24 in) Fork oil per fork leg 635 ml (21.47 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 196) 22.8 Shock absorber Shock absorber article number 15.18.7L.10 Shock absorber WP Performance Systems 4618 with Pro‑Lever linkage Compression damping, high-speed Comfort 2 turns...

  • Page 192: Chassis Tightening Torques

    TECHNICAL DATA Hard 85 N/mm (485 lb/in) Spring length 220 mm (8.66 in) Gas pressure 10 bar (145 psi) Static sag 18 mm (0.71 in) Riding sag 70… 80 mm (2.76… 3.15 in) Fitted length 395 mm (15.55 in) Shock absorber fluid ( p.

  • Page 193: Nm (1.5 Lbf Ft) Loctite

    TECHNICAL DATA Screw, exhaust heat shield 8 Nm (5.9 lbf ft) Loctite ® 243™ – Screw, fuel hose clamp on fuel tank 5 Nm (3.7 lbf ft) – Screw, fuel level sensor 3 Nm (2.2 lbf ft) – Screw, fuel pump 4 Nm (3 lbf ft) –...

  • Page 194: Nm (4.4 Lbf Ft) Loctite

    TECHNICAL DATA Screw, front brake disc 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, ignition lock 10 Nm (7.4 lbf ft) Loctite ® 243™ – Screw, lower radiator bracket 8 Nm (5.9 lbf ft) Loctite ® 243™ Screw, magnetic holder on side stand 6 Nm (4.4 lbf ft) –...
  • Page 195 TECHNICAL DATA – Screw, handlebar clamp 20 Nm (14.8 lbf ft) Screw, heel protector M8x12 5 Nm (3.7 lbf ft) Loctite ® 243™ – Screw, license plate holder, top 20 Nm (14.8 lbf ft) Screw, main silencer clamp 12 Nm (8.9 lbf ft) Copper paste –...
  • Page 196 TECHNICAL DATA Screw, bottom steering head M20x1.5 60 Nm (44.3 lbf ft) Loctite ® 243™ – Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) – Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft)

  • Page 197: Substances

    SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®...
  • Page 198 SUBSTANCES – KTM LC4 2007+ Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Synthetic engine oil Recommended supplier Motorex ® – Cross Power 4T Engine oil (SAE 10W/50) Standard/classification –...
  • Page 199 SUBSTANCES Hydraulic fluid (15) Standard/classification – 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. Recommended supplier Motorex ® – Hydraulic Fluid 75 Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –...

  • Page 200: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Recommended supplier Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Long-life grease Recommended supplier Motorex ® – Bike Grease 2000 Motorcycle cleaner Recommended supplier Motorex ® – Moto Clean Off-road chain spray Recommended supplier Motorex ®...
  • Page 201 AUXILIARY SUBSTANCES Perfect Finish and high gloss polish for paints Recommended supplier Motorex ® – Moto Polish & Shine 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 ®...

  • Page 202: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.

  • Page 203: Index Of Special Terms

    INDEX OF SPECIAL TERMS Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces Malfunction indicator lamp Indicator lamp that supports vehicle diagnostics through flash codes On-board diagnosis Vehicle system that monitors emission- and safety-related values...

  • Page 204: List Of Abbreviations

    LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 205: Lisy Of Symbols

    LISY OF SYMBOLS 28.1 Red symbols Red symbols indicate an error condition that requires immediate intervention. The temperature warning lamp lights up red – The coolant temperature has reached a critical value. The oil pressure warning lamp lights up red – The oil pressure is too low. The battery warning lamp lights up red –...
  • Page 206 LISY OF SYMBOLS The idling speed indicator lamp lights up green – The transmission is shifted to idle. The high beam indicator lamp lights up blue – The high beam is switched on.

  • Page 207: Index

    INDEX INDEX Brake linings front brake, changing ......102 ABS ......... 96 front brake, checking .
  • Page 208 INDEX Combination instrument Engine clock, setting ....... . 32 running in ........43 coolant temperature indicator .
  • Page 209 INDEX Foot brake lever ....... . Headlight bulb, changing ......139 basic position, adjusting .
  • Page 210 INDEX Rear wheel installing ........118 Oil filter removing .
  • Page 211 INDEX Shock absorber article number ..... . . 22 Tire condition checking ........121 Side stand .
  • Page 212 *3213395en* 3213395en 09/2015 KTM Sportmotorcycle GmbH Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com...

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