KTM 690 SMC Owner's Manual
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KTM 690 SMC Owner's Manual

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OWNER'S MANUAL
2008
690 SMC USA
ART. NO. 3211305en

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  • Page 1 OWNER'S MANUAL 2008 690 SMC USA ART. NO. 3211305en...
  • Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, as well as printing and other errors.
  • Page 4 Reproduction, even in part, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) Within the meaning of 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

    CONTENTS Combination instrument - control lamps ......32 CONTENTS MEANS OF REPRESENTATION ..........7 Combination instrument - Display ........33 IMPORTANT NOTES ............... 8 Combination instrument - speed display ......34 Overview of warning labels..........10 Setting kilometers or miles ..........34 VIEW OF VEHICLE..............
  • Page 6 Adjusting chain tension............. 79 Important maintenance work to be carried out by an Checking rear sprocket / engine sprocket for wear ....81 authorized KTM workshop. (as additional order)....61 Checking chain wear ............82 MAINTENANCE WORK ON CHASSIS AND ENGINE ....63 Adjusting chain guide ...
  • Page 7 CONTENTS Tire condition checking........... 107 Adjusting play in gas Bowden cable  ......139 Checking spoke tension........... 108 Checking engine oil level..........140 Checking tire air pressure ..........109 Changing engine oil and oil filter, cleaning oil screens  ..............140 Removing the seat ............110 Mounting the seat ............
  • Page 8 CONTENTS SUBSTANCES..............173 AUXILIARY SUBSTANCES........... 176 STANDARDS..............178 INDEX ................179...

  • 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 done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.

  • Page 10: Important Notes

    IMPORTANT NOTES 2 I MPORTANT NOTES Use definition KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race courses or offroad. Info The motorcycle is authorized for public road traffic in the homologous version only.
  • Page 11 Spare parts, accessories In the interests of your own safety, use only spare parts and accessories approved and/or recommended by KTM, and have these fitted in an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.

  • Page 12: Overview Of Warning Labels

    IMPORTANT NOTES Overview of warning labels 100330-10...
  • Page 13 IMPORTANT NOTES Type label, Canada Type label, USA Information, emission control Information, noise emission Information, suspension setting Information, chain tension Information, fuel evaporation system Information, putting into operation 100341-01 Type label, Canada...
  • Page 14 IMPORTANT NOTES 100340-01 Type label, USA 100339-01 Information, emission control...
  • Page 15 IMPORTANT NOTES 100342-01 Information, noise emission Information, suspension setting 100344-01...
  • Page 16 IMPORTANT NOTES Information, chain tension 100338-01 Information, fuel evaporation system 100336-01 Information, putting into operation 700210-01...
  • Page 17 IMPORTANT NOTES notes/warnings Be sure to pay attention to the notes and warnings given here. Info Various notes and warning stickers are attached to the vehicle. Do not remove any notes and warning stickers. If these are removed, you or other persons may not recognize potential danger and therefore be liable to injury. Grades of risks Danger Danger of leading to immediate, certain, serious, permanent injuries or death.
  • Page 18 Noise emission warranty KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.
  • Page 19 Consumer rights Limited warranty claims should be directed to an authorized KTM dealer. If you are not satisfied, please contact: KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA Telephone: (440) 985–3553...

  • Page 20: View Of Vehicle

    VIEW OF VEHICLE 3 V IEW OF VEHICLE View of vehicle, front left side 100328-10...
  • Page 21 VIEW OF VEHICLE Hand brake lever Clutch lever Seat Filler cap Front brake caliper Shift lever Engine number Side stand Footrest Seat release strap...

  • Page 22: View Of Vehicle, Rear Right Side

    VIEW OF VEHICLE View of vehicle, rear right side 100329-10...
  • Page 23 VIEW OF VEHICLE Ignition/steering lock Light switch, flasher switch, horn button Rear mirror Combination instrument Emergency OFF switch, electric starter button Throttle grip Rear brake caliper Shock absorber rebound damping Foot brake pedal Engine oil level viewer...

  • Page 24: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS 4 L OCATION OF SERIAL NUMBERS Chassis number The chassis number  is stamped on the steering head on the right.  100217-10 Type label Type label  is located on the upper right frame tube below the seat. ...

  • Page 25: Key Number

    LOCATION OF SERIAL NUMBERS Key number The key number  can be found on the KEYCODECARD.  Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place. 100179-10 Engine number The engine number  is stamped on the left side of the engine under the engine sprocket. ...

  • Page 26: Fork Part Number

    LOCATION OF SERIAL NUMBERS Fork part number The fork part number  is stamped on the inner side of the fork stub.  600480-10 Shock absorber part number Shock absorber part number  can be viewed from the right side.  100216-10...

  • Page 27: Operating Elements

    OPERATING ELEMENTS 5 O PERATING ELEMENTS Clutch lever The clutch lever  is fitted on the left side of the handlebar.  The clutch is hydraulically operated and self-adjusting. 600481-10 Hand brake lever The hand break lever  is fitted on the right side of the handlebar. ...

  • Page 28: Light Switch

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

  • Page 29: Headlight Flasher Switch

    OPERATING ELEMENTS Headlight flasher switch The headlight flasher switch  is fitted on the left side of the handlebar.  Possible states • Headlight flasher switch in neutral position Headlight flasher switch pressed – In this position, the headlight flasher (high beam) •...

  • Page 30: Flasher Switch

    OPERATING ELEMENTS Flasher switch The flasher switch  is fitted on the left side of the handlebar.  Possible states Flasher light off Flasher light, left, on – Flasher switch pressed to the right. The flasher switch returns automatically to the central position after use. Flasher light, right, on – Flasher switch pressed to the right.

  • Page 31: Horn Button

    OPERATING ELEMENTS Horn button The horn button  is fitted on the left side of the handlebar.  Possible states • Horn button  in neutral position pressed – The horn is operated in this position. • Horn button  100224-10 Emergency OFF switch 5.10 The emergency OFF switch ...

  • Page 32: Electric Starter Button

    OPERATING ELEMENTS Electric starter button 5.11 The electric starter button  is fitted on the right side of the handlebar.  Possible states • Electric starter button  in basic position pressed – In this position, the electric starter is actuated. • Electric starter button  100226-10 Ignition/steering lock 5.12...

  • Page 33: Combination Instrument

    OPERATING ELEMENTS Combination instrument 5.13 The combination instrument is attached in fromt of the handlebar. The combination instrument is divided into 4 function areas.  Function buttons  Tachometer  Indicator lights  Display  700116-01 Combination instrument - function buttons 5.14 Press the MODE button ...

  • Page 34: Combination Instrument - Tachometer

    OPERATING ELEMENTS Combination instrument - tachometer 5.15 The tachometer  displays the engine speed in revolutions per minute.  The red marking  shows the excess engine speed range.  100118-10 Combination instrument - control lamps 5.16 The indicator lamps provide additional information on the operating state of the motorcycle. Possible states Flashing indicator flashes green in flash rhythm – Flasher light is switched Idling speed indicator lamp lights up green – Transmission is in neutral.

  • Page 35: Combination Instrument - Display

    OPERATING ELEMENTS Battery warning lamp lights up – Voltage in electrical system too low. Combination instrument - Display 5.17 When you switch on the ignition, all display segments light up for a second as a function test. 700118-01 LEnGTth Following the display function test, the wheel circumference LEnGth is shown for one sec- ond.

  • Page 36: Combination Instrument - Speed Display

    OPERATING ELEMENTS Combination instrument - speed display 5.18 The speed  is displayed in kilometers per hour km/h or miles per hour Mph.  700114-01 Setting kilometers or miles 5.19 Info If you change the unit, the ODO value is retained and converted accordingly. Making the setting according to the country.

  • Page 37: Combination Instrument - Time

    OPERATING ELEMENTS – Switch on the ignition by turning the ignition key in the position  . – Press the MODE button several times 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 38: Combination Instrument - Odo Display

    OPERATING ELEMENTS – Switch on the ignition by turning the ignition key in the position  . – Press the MODE button several times until the ODO display mode is active. – Keep the MODE button and the SET button pressed simultaneously. The time begins to flash. – Press the MODE button to adjust the hour.

  • Page 39: Combination Instrument - Setting/Resetting Trip 2 Display

    OPERATING ELEMENTS – Switch on the ignition by turning the ignition key in the position  . – Press the MODE button several times until the TRIP 1 display mode is active. – Keep the SET button pressed. The TRIP 1 display is at 0.0. 700121-01 Combination instrument - setting/resetting TRIP 2 display 5.24 Info The tripmaster TRIP 2 operates constantly and counts up to 999.9.

  • Page 40: Combination Instrument - Trip F Display

    OPERATING ELEMENTS Combination instrument - TRIP F display 5.25 When the fuel level reaches the reserve mark, the display automatically changes to TRIP F and begins to count from 0.0, regardless of which display mode was previously active. Info Parallel to the TRIP F display, the fuel warning light begins to light up. 700123-01 Combination instrument - coolant temperature indicator 5.26...

  • Page 41: Opening Filler Cap

    OPERATING ELEMENTS Opening filler cap 5.27 – Lift the cover of the filler cap  and insert the ignition key.  – Turn the ignition key 90° counterclockwise and remove the filler cap. Info The filler cap has a tank air vent system. 100227-10 Closing filler cap 5.28...

  • Page 42: Handrails

    OPERATING ELEMENTS Handrails 5.29 The handrails  are used for moving the motorcycle around.  When you have a passenger, the passenger can hold on the handrails during the journey. 100229-10 Seat release 5.30 The seat can be released using strap  ...

  • Page 43: Passenger Footrests

    OPERATING ELEMENTS Passenger footrests 5.31 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. • 600640-01 Shift lever 5.32 The shift lever  is mounted on the left side of the engine.

  • Page 44: Foot Brake Pedal

    OPERATING ELEMENTS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 600484-11 Foot brake pedal 5.33 The footbrake pedal  is located in front of the right footrest.  The footbrake pedal operates the rear brake.

  • Page 45: Side Stand

    OPERATING ELEMENTS Side stand 5.34 The side stand  is coupled with the safety electric starter system - see the riding instruc-  tions. Possible states Side stand folded out – The vehicle can be supported on the side stand. The safety •...

  • Page 46: General Tips On Putting Into Operation

    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 characteristics 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 47: Running In The Engine

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

  • Page 48: Loading The Vehicle

    GENERAL TIPS ON PUTTING INTO OPERATION – Avoid fully opening the throttle! Loading the vehicle Warning Danger of accidents Unstable riding behavior. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage.
  • Page 49 GENERAL TIPS ON PUTTING INTO OPERATION Warning Danger of accidents Unstable handling characteristics due to slipped baggage. – Check the way your baggage is fixed regularly. Warning Danger of burns A hot exhaust system can burn baggage. – Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system. –...

  • Page 50: Riding Instructions

    RIDING INSTRUCTIONS 7 R IDING INSTRUCTIONS Checks before putting into operation Info Make sure that the motorcycle is in a perfect technical condition before use. In the interests of riding safety, make a habit of making a general check before you ride. –...

  • Page 51: Starting

    RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are poisonous and can 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 a closed space. Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety equipment may be damaged.
  • Page 52 RIDING INSTRUCTIONS – Turn the emergency OFF switch to the position  . – Switch on the ignition by turning the ignition key in the position  . After switching on the ignition, you can hear the fuel pump working for about 2 seconds.

  • Page 53: Starting Up

    RIDING INSTRUCTIONS Starting up – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully. Shifting, riding Warning Danger of accidents An abrupt load alterations can cause the vehicle to get out of control. –...
  • Page 54 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 55 If you continue with the coolant temperature warning lamp alight, you may have engine failure. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. – When conditions allow (incline, road situation, etc.), you can shift into a higher gear.

  • Page 56: Braking

    Clean or dry dirty or wet brakes by riding and braking gently. Warning Danger of accidents Reduced braking caused by spongy pressure point of front or rear brake. – Have the brake system checked in an authorized KTM workshop, and do not ride any further.

  • Page 57: Stopping, Parking

    RIDING INSTRUCTIONS Warning Danger of accidents Brake system failure. – If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take your foot off the foot brake pedal if you do not want to brake. Warning Danger of accidents Longer stopping distance due to higher overall weight.
  • Page 58 RIDING INSTRUCTIONS Warning Danger of burns Some vehicle components get very hot when the machine is driven. – Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these components to cool down before starting work on them. Note Danger of damage Danger of damage by the vehicle running away or falling over.

  • Page 59: Refueling

    RIDING INSTRUCTIONS – Lock the steering by moving the handlebar to the left, pressing down the ignition key in the position  and turning it to the position  . To make locking the steering easier, move the handlebar a little to the left and right. Remove the ignition key. Refueling Danger Fire hazard Fuel can easily catch fire.
  • Page 60 RIDING INSTRUCTIONS – switch off engine. – Open the filler cap. ( S. 39) – Fill the fuel tank with fuel up to measurement   Guideline Measurement of  20 mm (0.79 in)  Fuel tank content 12 l (3.2 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( S.

  • Page 61: Greasing And Service Table

    GREASING AND SERVICE TABLE 8 G REASING AND SERVICE TABLE Important maintenance work to be carried out by an authorized KTM workshop. K10N K50A K100A Engine Change engine oil and oil filter, clean oil screens.  S. 140) • • •...
  • Page 62 GREASING AND SERVICE TABLE K10N K50A K100A Attachments Check the functioning of the electrical equipment. • • • • • Check screws and nuts for tightness. • • • • • Brakes Check the front brake linings. ( S. 88) •...

  • Page 63: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop. (As Additional Order)

    K50A: every 5,000 km (3,107 mi) / after every race K100A: every 10,000 km (6,214 mi) J1A: annually J2A: every 2 years Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) K100A Carry out a complete fork service.  •...
  • Page 64 GREASING AND SERVICE TABLE J2A: every 2 years...

  • Page 65: Maintenance Work On Chassis And Engine

    MAINTENANCE WORK ON CHASSIS AND ENGINE 9 M AINTENANCE WORK ON CHASSIS AND ENGINE Jacking up front of motorcycle Note Danger of damage Danger of damage by the vehicle running away or falling over. – Always place the vehicle on a firm and even surface. –...

  • Page 66: Jacking Up Rear Of Motorcycle

    MAINTENANCE WORK ON CHASSIS AND ENGINE Jacking up rear of motorcycle Note Danger of damage Danger of damage by the vehicle running away or falling over. – Always place the vehicle on a firm and even surface. – Insert the work stand adapter in the work stand and screw it into the link forks. Work stand adapter (61029055110) Work stand rear (61029055100) –...

  • Page 67: Fork/Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE 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 68: Adjusting Rebound Damping Of Fork

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn back counterclockwise the number of clicks corresponding to the fork type. 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 suspension damping.

  • Page 69: Compression Damping Of Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn back counterclockwise the number of clicks corresponding to the fork type. Guideline Rebound damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks full payload 5 clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

  • Page 70: Adjusting High-Speed Compression Damping Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn the adjusting screw  clockwise with a screwdriver until it stops.  Info Do not loosen nut   – Turn back counterclockwise the number of clicks corresponding to the shock absorber type. Guideline Compression damping, low-speed Comfort 20 clicks...
  • Page 71 MAINTENANCE WORK ON CHASSIS AND ENGINE Info The high-speed setting can be seen during the fast compression of the shock absorber. – Turn the adjusting screw  clockwise with an open-ended spanner until it stops.  Info Do not loosen nut  ...

  • Page 72: Adjusting Rebound Damping Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting rebound damping of the shock absorber 9.11 Danger Danger of accidents The shock absorber is under high pressure. – The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any mainte- nance on it yourself.

  • Page 73: Cleaning Dust Boots Of Fork Legs

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove bleeder screws  briefly.  Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. Info Carry out this action on both fork legs. 100248-10 Cleaning dust boots of fork legs 9.13 –...

  • Page 74: Removing The Fork Protector

    MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of accidents Reduced braking due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. – Clean and oil the dust boots and inner fork tube of both fork legs.

  • Page 75: Installing The Fork Protector

    Danger of accidents Unsafe riding behavior due to incorrect steering head bearing play. – The steering head bearing play should be adjusted immediately in an authorized KTM workshop. Info If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time.

  • Page 76: Adjusting Play Of Steering Head Bearing

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: –...

  • Page 77: Handlebar Position

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount and tighten screw   Guideline Screw, steering stem 20 Nm Loctite ® 243™ (14.8 lbf ft) – Check play of steering head bearing.  S. 73) – Remove the motorcycle from the work stand. Handlebar position 9.18 On the upper triple clamp, there are 2 holes at a distance ...

  • Page 78: Adjusting Handlebar Position

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting handlebar position  9.19 – Remove the four screws  . Remove the handlebar clamp. Remove the handlebar and  0 0 1 lay it to one side. 0 0 2 Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines.

  • Page 79: Adjusting The Handlebar Angle

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the handlebar angle  9.20 – Loosen screw   – Move the handlebar to the desired position and slightly tichten the screws. – Move the handlebar carefully in both directions as far as it will go. »...

  • Page 80: Checking The Chain Tension

    MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of accidents Reduced braking due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 81: Adjusting Chain Tension

    MAINTENANCE WORK ON CHASSIS AND ENGINE – 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 ...
  • Page 82 MAINTENANCE WORK ON CHASSIS AND ENGINE – Lean the motorcycle on the side stand. – Shift gear to neutral. – Loosen nut   – Loosen nuts   – Adjust the chain tension by turning the adjusting screws  left and right. ...

  • Page 83: Checking Rear Sprocket / Engine Sprocket For Wear

    The engine sprocket, rear sprocket and chain should always be replaced together. For safety reasons, the chain has no chain joint. Always have the chain replaced in an authorized KTM workshop, where the necessary chain rivet tool is available. 100132-10 –...

  • Page 84: Checking Chain Wear

    A new chain will wear faster on an old, worn rear sprocket or engine 1 2 3 16 17 18 sprocket. 400409-10 For safety reasons, the chain has no chain joint. Always have the chain changed in an authorized KTM workshop, where they have the necessary special tools.

  • Page 85: Adjusting Chain Guide

    Mount and tighten screws  and    Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 600635-10 Checking brake discs 9.28 Warning Danger of accidents Reduced braking due to worn brake discs. – Worn brake discs should be replaced immediately in an authorized KTM workshop.

  • Page 86: Adjusting Basic Position Of Handbrake Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement   Info Wear reduces the thickness of the brake disc around the area used by the brake linings.

  • Page 87: Checking Front Brake Fluid Level

    Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. – The brake fluid level must not fall below the center of the level viewer ...
  • Page 88 If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –...

  • Page 89: Brake Linings

    Clean up overflowed or spilt brake fluid immediately with water. Brake linings 9.32 The brake linings fitted by KTM were tested over long periods and ensure optimal braking properties. The type names of brake pads are entered in the homologation documents. Info Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles.

  • Page 90: Checking The Front Brake Linings

    If the minimum thickness is less than specified: – Change the front brake linings.  S. 88) 600625-10 Changing the front brake linings  9.34 Warning Danger of accidents Improper brake maintenance and repair. – Always have your brake system maintained and repaired in an authorized KTM workshop.
  • Page 91 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 92: Removing Front Brake Linings

    Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water. 100254-12 Removing front brake linings  9.35 Warning Danger of accidents Improper brake maintenance and repair. – Always have your brake system maintained and repaired in an authorized KTM workshop.

  • Page 93: Mounting Front Brake Linings

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Press the spring hanger of the spring  forwards and withdraw the bolt    – Take off the springs  . Remove brake linings    400421-11 – Remove screw  and spacing sleeve  . Remove the brake caliper. ...
  • Page 94 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 95: Checking Free Play Of Foot Brake Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking free play of foot brake lever 9.37 Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can fail due to overheating.

  • Page 96: Checking Rear Brake Fluid Level

    Danger of accidents Brake system failure. – MINIf the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.

  • Page 97: Topping Up Brake Fluid Of Rear Brake

    MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. – Stand the vehicle upright. –...
  • Page 98 MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –...

  • Page 99: Checking The Rear Brake Linings

    If the minimum thickness is less than specified: – Change the rear brake linings.  S. 97) 100260-10 Changing rear brake linings  9.42 Warning Danger of accidents Improper brake maintenance and repair. – Always have your brake system maintained and repaired in an authorized KTM workshop.
  • Page 100 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 101 MAINTENANCE WORK ON CHASSIS AND ENGINE – Stand the vehicle upright. – Remove screw cover  with membrane    – Press the brake caliper by hand on to the brake disc in order to press back the brake piston. Ensure that brake fluid does not overflow from the brake fluid reservoir and suc- tion it off if necessary.

  • Page 102: Removing Front Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Insert the brake pads, insert the bolt and mount the split pin. – Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot. –...
  • Page 103 MAINTENANCE WORK ON CHASSIS AND ENGINE – Loosed screw  and screw    – Screw out screw  about 6 turns, press your hand on the screw to push the wheel spin-  dle out of the fork stub. Remove screw  ...

  • Page 104: Installing The Front Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the front wheel  9.44 Warning Danger of accidents Reduced braking due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

  • Page 105: Removing Rear Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc. – Take the front from the work stand. ( S. 63) – Pull the front wheel brake and push down hard on the fork several times to align the fork legs.

  • Page 106: Installing The Rear Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Push the rear wheel forwards as far as possible and take the chain off the rear sprocket. Warning Danger of accidents Reduced braking due to damaged brake discs. – Always lay the wheel down in such a way that the brake disc is not damaged. –...
  • Page 107 MAINTENANCE WORK ON CHASSIS AND ENGINE – Check parts for damage and wear. Replace damaged or worn parts. – Remove the bushing  . Clean and grease the roll surfaces of the bushing and the shaft  seal ring   Long-life grease ( S.

  • Page 108: Checking The Rear Hub Rubber Dampers

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the rear hub rubber dampers  9.47 Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged. –...

  • Page 109: Tire Condition Checking

    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 characteristics 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 110: Checking Spoke Tension

    Danger of accidents Unstable riding behavior due to loose spokes. – If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop. Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.

  • Page 111: Checking Tire Air Pressure

    MAINTENANCE WORK ON CHASSIS AND ENGINE – To check spoke tension, tap each spoke with a screwdriver. Guideline You should hear a high note. Spoke nipple, front wheel M4,5 4 Nm (3 lbf ft) Spoke nipple, rear wheel 4 Nm (3 lbf ft) Info If you hear different tone frequencies from different spokes, this is an indication 600632-01 of different spoke tensions.

  • Page 112: Removing The Seat

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount dust cap. Removing the seat 9.51 – Pull on strap  and raise the rear of the seat at the same time.  – Pull back the seat and lift it off. 100230-10 Mounting the seat 9.52 –...

  • Page 113: Removing The Battery

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the battery  9.53 Warning Risk of injury Battery acid and battery gases cause serious cauterization. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...

  • Page 114: Installing The Battery

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the battery  9.54 – Slide the battery into the battery rack. Info The battery terminals must be at the rear. – Attach the positive cable and mount positive terminal cover   – Position retaining bracket  ...
  • Page 115 MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Environmental hazard Components and battery acid are a danger to the environment. – Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator. Warning Environmental hazard Problem materials cause environmental damage. –...

  • Page 116: Changing The Main Fuse

    MAINTENANCE WORK ON CHASSIS AND ENGINE – 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 generator. With this device, you cannot overcharge the battery. Info Never remove the lid ...
  • Page 117 A reserve fuse  is located in the starter relay.  – Fit a new main fuse. Fuse (58011109130) ( S. 165) 600605-10 Info If the new fuse burns out, contact an authorized KTM workshop. – Check the functioning of the electrical equipment.

  • Page 118: Changing Fuses Of Individual Power Consumers

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Attach the protection covers. – Mount the seat. ( S. 110) – Set the clock. ( S. 35) Changing fuses of individual power consumers 9.57 Info The fuse box containing the fuses of individual power consumers is located under the seat. –...
  • Page 119 MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove defective fuse. Guideline Fuse 1 - 10A - ignition, combination instrument, alarm system (optional) Fuse 2 - 10A - clock, ignition (EFI control unit) Fuse 3 - 10A - throttle valve control unit Fuse 4 - 10A - fuel pump Fuse 5 - 10A - radiator fan Fuse 6 - 10A - horn, brake light, flasher light, alarm system (optional) Fuse 7 - 15A - high beam, low beam, parking light, tail light, license plate lamp...

  • Page 120: Adjusting The Engine Characteristic

    Fuse (75011088015) ( S. 165) Info If the new fuse burns out, contact an authorized KTM workshop. Replace the spare fuse in the fuse box so that it will be available if needed. – Check the functioning of the power consumer.
  • Page 121 MAINTENANCE WORK ON CHASSIS AND ENGINE – Pull the Map‑Select switch and holder  upward off of the retaining bracket.  – Pull the Map‑Select switch out of the holder. 600641-10 – Turn the adjusting wheel until the desired digit is next to marking  ...

  • Page 122: Removing Headlight Mask With Headlight

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing headlight mask with headlight 9.59 – Switch off all power-consuming components and switch off the engine. – Protect the fender against damage by covering it with a cloth. – Remove the screws  on the left and right. ...

  • Page 123: Refitting The Headlight Mask With The Headlight

    MAINTENANCE WORK ON CHASSIS AND ENGINE Refitting the headlight mask with the headlight 9.60 – Connect the connectors of headlight  and flasher lights    – Check lighting function. 100294-11 – Remove the cloth from the fender, attach the headlight mask to points  on the fender ...

  • Page 124: Changing The Headlight Bulb

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Position brake-hose guide  . Mount and tighten screws    Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 100296-10 Changing the headlight bulb 9.61 Note Damage to reflector Keep the glass of the bulb free of grease. –...

  • Page 125: Changing The Parking Light Bulb

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Detach spring bar   – Remove headlight bulb   – Insert a new headlight bulb into the headlight housing. Headlight (H4/P43t) ( S. 165) – Fit the headlight bulb in the headlight using the spring bar. –...

  • Page 126: Changing The Rear Lamp

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Pull bulb socket  out of the reflector.  – Pull parking light bulb  out of the bulb socket.  – Check parts for damage and wear. Replace damaged or worn parts. – Insert a new parking light bulb into the bulb socket. Parking light (W2,1x9,5d) ( S.

  • Page 127: Changing The Flasher Bulb

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Check the function of the rear lamp and the brake light. – Check that the seal  is correctly seated. Position the lens.  – Insert the screws and turn them first counterclockwise until you feel them click into the thread.

  • Page 128: Checking Headlamp Setting

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Check the flasher function. Checking headlamp setting 9.65 – On a light-colored wall with a horizontal area in front of it, make a mark as high as the 0 0 A center of the low beam headlight. –...

  • Page 129: Removing The Air Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Use a screwdriver (see illustration) 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 (mark is applied under: Checking headlight adjustment). Info Turn clockwise to increase the light range, turn counterclockwise to reduce the light range.

  • Page 130: Installing The Air Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. –...

  • Page 131: Cooling System

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount and tighten screws   Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Mount the seat. ( S. 110) 100285-11 Cooling system 9.69 The water pump  in the engine forces the coolant to flow. ...

  • Page 132: Checking The Antifreeze And Coolant Level

    MAINTENANCE WORK ON CHASSIS AND ENGINE The coolant is cooled by the air stream and a radiator fan  , which is controlled by a ther-  moswitch. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect.
  • Page 133 MAINTENANCE WORK ON CHASSIS AND ENGINE Condition Engine is cold. – Stand the motorcycle on its side stand on a horizontal surface. – Remove the cap of the compensating tank   – Check antifreeze of coolant. −25… −45 °C (−13… −49 °F) »...

  • Page 134: Checking The Coolant Level

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Screw off the radiator cap   – Check antifreeze of coolant. −25… −45 °C (−13… −49 °F) » If the antifreeze of the cooling liquid does not meet specifications: – Correct antifreeze of coolant. – Check the coolant level in the radiator.
  • Page 135 MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of poisoning Coolants are poisonous and a health hazard. – Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and con- tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.

  • Page 136: Draining Coolant

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Screw off the radiator cap  and check the coolant level in the radiator.  The radiator must be completely full. » If the level of the cooling liquid does not meet specifications: – Correct the coolant level and find out the cause of the loss.

  • Page 137: Filling The Cooling System

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Stand the vehicle upright. – Place a suitable container under the engine. – Remove screw  . Remove the radiator cap.  – Completely drain the coolant. – Fit screw  with a new seal and tighten it. ...
  • Page 138 MAINTENANCE WORK ON CHASSIS AND ENGINE – Refill the coolant. Alternative 1 Coolant ( S. 173) Alternative 2 Coolant (mixed ready to use) ( S. 173) – Fill the radiator completely with coolant. Mount radiator cap   600619-10 – Remove the cap from compensating tank  and add coolant to the level shown in the ...

  • Page 139: Adjusting Basic Position Of Clutch Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting basic position of clutch lever 9.74 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 140: Checking Play In Gas Bowden Cable

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

  • Page 141: Adjusting Play In Gas Bowden Cable

    MAINTENANCE WORK ON CHASSIS AND ENGINE Danger Danger of poisoning Exhaust gases are poisonous and can 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 a closed space. –...

  • Page 142: Checking Engine Oil Level

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking engine oil level 9.78 Info The engine oil level must be checked when the engine is at operating temperature. – Stand the motorcycle upright on a horizontal surface. Condition The engine is at operating temperature. –...

  • Page 143: Draining Engine Oil

    MAINTENANCE WORK ON CHASSIS AND ENGINE Draining engine oil  9.80 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. – Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 144: Removing The Oil Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Thoroughly clean the oil drain plug with a magnet. – Check parts for damage and wear. Replace damaged or worn parts. – Refit the oil drain plug with the magnet and seal ring and tighten it. Guideline Oil drain plug with magnet M12x1,5...
  • Page 145 MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screws  . Remove oil filter cover  with O-ring.   – Pull the oil filter insert  out of the oil filter casing.  Circlip pliers reverse (51012011000) 100202-10 – Remove screws  . Remove oil filter cover  with O-ring.

  • Page 146: Mounting Oil Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE Mounting oil filter  9.82 – Check parts for damage and wear. Replace damaged or worn parts. – Insert oil filter  and    – Oil the O-rings of the oil filter cover. Refit the oil filter cover  and ...
  • Page 147 MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove the plug  with the oil screen  and O-rings.   100205-10 – Remove the plug  with the oil screen  and O-rings.   – Drain the remaining engine oil. – Thoroughly clean parts and sealing area. –...

  • Page 148: Filling Up With Engine Oil

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Position oil screen  with O-rings.  – Refit plug  with O-ring and tighten it.  Guideline Plug, oil screen M20x1,5 15 Nm (11.1 lbf ft) 100208-10 Filling up with engine oil  9.84 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. –...

  • Page 149: Topping Up Engine Oil

    MAINTENANCE WORK ON CHASSIS AND ENGINE Topping up engine oil 9.85 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – Remove filler plug with O-ring  from the clutch cover and add engine oil. ...

  • Page 150: Troubleshooting

    Socket connector of cable harness oxidized Clean socket connector and treat it with contact spray. – Defect in fuel injection system Read the error memory with the KTM diagnostics tool and correct the fault. – Engine has too little power. Air filter very dirty...
  • Page 151 Engine has too little power. Fuel filter very dirty Have the fuel filter changed. – Defect in fuel injection system Read the error memory with the KTM diagnostics tool and correct the fault. – Engine overheats. Too little coolant in cooling system Check the cooling system for leakage.
  • Page 152 TROUBLESHOOTING Faults Possible cause Action – Headlight and parking light not functioning Fuse 7 blown Change the fuses of individual power consumers. ( S. 116) – Flasher light, brake light and horn not Fuse 6 blown Change the fuses of individual power functioning consumers.

  • Page 153: Flashing Code

    FLASHING CODE FLASHING CODE Fault Description Possible cause Action – FI warning lamp (MIL) flashes Malfunction in ignition pulse Check the ignition pulse briefly 2x generator circuit generator.  – FI warning lamp (MIL) flashes Input signal from throttle valve Check the throttle valve sen- briefly 6x sensor too low/high sor. ...
  • Page 154 FLASHING CODE Fault Description Possible cause Action – FI warning lamp (MIL) flashes 2x Malfunction in voltage supply Check the throttle valve con- long, 7x short circuit of throttle valve control trol unit voltage supply.  unit – FI warning lamp (MIL) flashes 3x Malfunction in injection valve Check the injection long, 3x short...
  • Page 155 FLASHING CODE Fault Description Possible cause Action – FI warning lamp (MIL) flashes 9x Throttle valve position not plau- Check the throttle valve long sible position.  – FI warning lamp (MIL) flashes 9x Malfunction in CAN bus com- Check CAN bus communica- long, 1x short munication tion. ...

  • Page 156: Cleaning

    CLEANING CLEANING Cleaning motorcycle 12.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Problem materials cause environmental damage.
  • Page 157 CLEANING Warning Danger of accidents Reduced braking due to wet or dirty brakes. – Clean or dry dirty or wet brakes by riding and braking gently. – After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes. Info The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.

  • Page 158: Conservation For Winter Operation

    CONSERVATION FOR WINTER OPERATION CONSERVATION FOR WINTER OPERATION Conservation for winter operation 13.1 Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If you have ridden the vehicle on salted roads, clean it with cold water. Warm water would reinforce the effect of the salt. –...

  • Page 159: Storage

    Storage temperature of battery without direct sunshine. 0… 35 °C (32… 95 °F) – The storage place should be dry and not subject to large temperature differences. Info KTM recommends jacking up the motorcycle. – Jack up the rear of the motorcycle. ( S. 64) –...

  • Page 160: Putting Into Operation After Storage

    STORAGE – Cover the motorcycle with a porous sheet or blanket. 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 161: Technical Data - Engine

    TECHNICAL DATA - ENGINE TECHNICAL DATA - ENGINE Design 1-cyliner 4-stroke engine, water-cooled Displacement 654 cm³ (39.91 cu in) Stroke 80 mm (3.15 in) Bore 102 mm (4.02 in) Compression ratio 11,8:1 Control OHC, 4 valves controlled via rocker arm, chain drive Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust 34 mm (1.34 in) Valve play, cold...

  • Page 162: Capacity - Engine Oil

    TECHNICAL DATA - ENGINE 6th gear 23:20 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Generator 12 V, 224 W Spark plug NGK LKAR 8AI - 9 spark plug electrode gap 0.9 mm (0.035 in) Cooling Water cooling, permanent circulation of coolant by water pump Starting aid Electric starter, automatic decompressor Capacity - engine oil...

  • Page 163: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Plug, oil bore self-tapping 9 Nm (6.6 lbf ft) Loctite 243™ ® Screw, membrane fixation 2.5 Nm (1.84 lbf ft) Loctite 243™ ® Oil jet, conrod lubrication 2 Nm (1.5 lbf ft) Loctite 243™ – Hose clamp, intake flange 1.5 Nm (1.11 lbf ft) –...
  • Page 164 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Screw, engine housing 10 Nm (7.4 lbf ft) ® Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite 243™ ® Screw, shift lever 10 Nm (7.4 lbf ft) Loctite ® Screw, timing chain tensioning rail 10 Nm (7.4 lbf ft) Loctite 243™ ® Screw, starter motor 10 Nm (7.4 lbf ft) Loctite 243™...
  • Page 165 TECHNICAL DATA - ENGINE TIGHTENING TORQUES Screw, cylinder head Tightening sequence: lubricated with engine oil Tighten diagonally, beginning with the rear screw on the chain shaft. Step 1 15 Nm (11.1 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 45 Nm (33.2 lbf ft) Step 4 60 Nm (44.3 lbf ft) –...

  • Page 166: Technical Data - Chassis

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

  • Page 167: Lighting Equipment

    TECHNICAL DATA - CHASSIS Steering head angle 63° Wheelbase 1,480±15 mm (58.27±0.59 in) Seat height unloaded 900 mm (35.43 in) Ground clearance unloaded 290 mm (11.42 in) Weight without fuel 139.5 kg (307.5 lb.) Maximum permissible front axle load 150 kg (331 lb.) Maximum permissible rear axle load 200 kg (441 lb.) Maximum permissible overall weight 350 kg (772 lb.) Battery...

  • Page 168: Capacity - Fuel

    Front tire Rear tire 120/70 ZR 17 M/C 58W TL 160/60 ZR 17 M/C 69W TL Pirelli Dragon Supercorsa Pro Pirelli Dragon Supercorsa Pro For further information, see the Service section under: http://www.ktm.com Capacity - fuel 17.2 Fuel tank content 12 l (3.2 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( S. 175) Fuel reserve 2.5 l (2.6 qt.)

  • Page 169: Technical Data / Fork

    TECHNICAL DATA / FORK TECHNICAL DATA / FORK Fork part number 14.18.7D.12 Fork WP Suspension Up Side Down 4860 ROMA Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks Rebound damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks full payload 5 clicks Spring length with preload spacer(s) 480 mm (18.9 in)

  • Page 170: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 15.18.7D.12 Shock absorber WP Suspension 4618 with Pro‑Lever deflector Compression damping, high-speed Comfort 1.5 turns Standard 1 turn Sport 0.5 turn full payload 0.5 turn Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload...
  • Page 171 TECHNICAL DATA - SHOCK ABSORBER Static sag 20 mm (0.79 in) Riding sag 70… 80 mm (2.76… 3.15 in) Fitted length 400 mm (15.75 in)

  • Page 172: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Spoke nipple, front wheel M4,5 4 Nm (3 lbf ft) – Spoke nipple, rear wheel 4 Nm (3 lbf ft) – Remaining screws, chassis 4 Nm (3 lbf ft) – Screw, exhaust heat shield 8 Nm (5.9 lbf ft) –...
  • Page 173 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ® Screw, magnetic holder on side stand 10 Nm (7.4 lbf ft) Loctite 243™ – Screw, voltage regulator/rectifier 8 Nm (5.9 lbf ft) – Screw, SLS valve 4 Nm (3 lbf ft) ® Screw, ignition lock 10 Nm (7.4 lbf ft) Loctite 243™ ® Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite 243™...
  • Page 174 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw, side stand bracket 25 Nm (18.4 lbf ft) – Screw, connection lever on frame 30 Nm (22.1 lbf ft) – Remaining nuts, chassis 50 Nm (36.9 lbf ft) – Remaining screws, chassis 45 Nm (33.2 lbf ft) ® Screw, front brake caliper M10x1.25 45 Nm (33.2 lbf ft) Loctite 243™...

  • Page 175: Substances

    Brake fluid DOT 4 / DOT 5.1 according to – Specification – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Suppler Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 176 SAE ( S. 178) (SAE 10W/60) Specification – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding ® properties. KTM recommends Motorex products. Synthetic engine oil Suppler ® Motorex –...
  • Page 177 SUBSTANCES Specification – Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Suppler ® Motorex – Hydraulic Fluid 75 Super unleaded (ROZ 95 / RON 95 / PON 91) according to –...

  • Page 178: Auxiliary Substances

    AUXILIARY SUBSTANCES AUXILIARY SUBSTANCES Chain cleaner Specification – ® KTM recommends Motorex products. Suppler ® Motorex – Chain Clean 611 Cleaning and polishing materials for metal, rubber and plastic Specification – ® KTM recommends Motorex products. Suppler ® Motorex – Protect & Shine 645 Contact spray Specification –...
  • Page 179 AUXILIARY SUBSTANCES Long-life grease Specification – ® KTM recommends Motorex products. Suppler ® Motorex – Fett 2000 Motorcycle cleaner Specification – ® KTM recommends Motorex products. Suppler ® Motorex – Moto Clean 900 Onroad chain spray Specification – ® KTM recommends Motorex products. Suppler ®...

  • Page 180: Standards

    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 181: Index

    INDEX of rear brake, checking ......97 INDEX Removing front brake linings ..... 90 Accessories .
  • Page 182 INDEX Function buttons ......31 Engine characteristic Indicator lights ....... 32 adjusting .
  • Page 183 INDEX Bleeding fork legs ......70 removing ........120 Fork part number .
  • Page 184 INDEX Oil screen Rear wheel cleaning ........140 installing .
  • Page 185 INDEX Steering lock ........30 Stopping ........55 Storage .
  • Page 186 *3211305en* 3211305en 03/2008 Photo Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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