KTM 690 Duke 2018 Owner's Manual
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KTM 690 Duke 2018 Owner's Manual

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OWNER'S MANUAL
2018
690 Duke
Art. no. 3213748en

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  • Page 1 OWNER'S MANUAL 2018 690 Duke Art. no. 3213748en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art DEAR KTM CUSTOMER sports motorcycle that will give you enormous pleasure if you service and maintain it properly. We hope you enjoy your new ride! Enter the serial numbers of your vehicle below.
  • 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 assur- ance processes that lead to the maximum possible quality of the products. Issued by: TÜV Management Service KTM Sportmotorcycle GmbH Stallhofnerstraße 3...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Service ........... 23 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 8 Figures ........... 23 Symbols used ........8 Customer service......23 Formats used........9 VIEW OF VEHICLE ........26 SAFETY ADVICE.......... 10 View of vehicle, front left ....26 Use definition –...
  • Page 6 TABLE OF CONTENTS 6.4.5 Horn button ........ 38 7.10 "Trip 1" ........... 55 Switches on the right side of the 7.11 "Trip 2" ........... 56 handlebar........39 7.12 "General info" ........57 6.5.1 Emergency OFF switch ....39 7.13 "Set Favorites" ......... 57 6.5.2 Electric starter button ....
  • Page 7 TABLE OF CONTENTS Shifting, riding ........ 74 12.5 Removing the passenger seat .... 98 Engine braking control (MSR) .... 79 12.6 Mounting the passenger seat..... 99 Applying the brakes......79 12.7 Checking the chain for dirt....100 Stopping, parking......82 12.8 Cleaning the chain ......
  • Page 8 TABLE OF CONTENTS 13.9 Checking rear brake fluid level ..124 15.9 Changing the headlight bulb ... 165 13.10 Adding rear brake fluid ....125 15.10 Changing the parking light bulb..167 13.11 Checking the rear brake linings ..128 15.11 Changing the turn signal bulb ..
  • Page 9 TABLE OF CONTENTS 18 SERVICE WORK ON THE ENGINE ....190 22.6 Tires ..........223 22.7 Fork..........223 18.1 Checking the engine oil level... 190 22.8 Shock absorber ......224 18.2 Changing the engine oil and oil 22.9 Chassis tightening torques ....224 filter, cleaning the oil screens ..

  • Page 10: 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! Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary tools required.

  • Page 11: Formats Used

    MEANS OF REPRESENTATION 1 Indicates a voltage measurement. Indicates a current measurement. Indicates the end of an activity, including potential rework. Formats used The typographical formats used in this document are explained below. Proprietary name Indicates a proprietary name. Name ®...

  • Page 12: Safety Advice

    2 SAFETY ADVICE Use definition – intended use This vehicle has been designed and built to withstand the normal stresses and strains of road use. This vehicle is not suitable for use on race tracks or offroad. Info This vehicle is only authorized for operation on public roads in its homologated version. Misuse The vehicle must only be used as intended.

  • Page 13: Degrees Of Risk And Symbols

    SAFETY ADVICE 2 Info Various information and warning labels are attached in prominent locations on the model described. Do not remove any information or warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured. Degrees of risk and symbols Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the...

  • Page 14: Overview Of Labels

    2 SAFETY ADVICE Overview of labels E01054-10...
  • Page 15 SAFETY ADVICE 2 Type label, Canada Information, chain tension Information, putting into operation Information, emission control Information, noise emission Type label, USA E01048-10 Type label, Canada...

  • Page 16: Information, Chain Tension

    2 SAFETY ADVICE Information, chain tension 700207-01 Information, putting into operation 700210-01...

  • Page 17: Information, Emission Control

    SAFETY ADVICE 2 Information, emission control E01049-01 E01050-01 Information, noise emission...

  • Page 18: Reporting Safety Defects

    However, NHTSA cannot become involved in individual problems between you, your dealer, or KTM North America, Inc. To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1–888–327–4236 or visit the website www.nhtsa.dot.gov, or write to: NHTSA Headquarters, 1200 New Jersey Avenue, SE, West Building, Washington,...

  • Page 19: Noise Emission Warranty

    SAFETY ADVICE 2 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 20: Tampering Warning

    2 SAFETY ADVICE 2.10 Tampering warning Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof: 1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replace- ment, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any...

  • Page 21: Protective Clothing

    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 22: Work Rules

    2 SAFETY ADVICE In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. 2.13 Work rules Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered using the number in parentheses.

  • Page 23: Owner's Manual

    The Owner's Manual is an important component of the vehicle and must be handed over to the new owner if the vehicle is sold. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. International KTM Website: http://www.ktm.com...

  • Page 24: 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.

  • Page 25: 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.
  • Page 26 3 IMPORTANT NOTES A list of authorized KTM dealers can be found on the KTM website. International KTM Website: http://www.ktm.com...
  • Page 27 3 IMPORTANT NOTES...

  • Page 28: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left E01052-10...
  • Page 29 VIEW OF VEHICLE 4 Clutch lever ( p. 34) Seat Passenger seat Handrails ( p. 45) Seat lock ( p. 44) Side stand ( p. 47) Shift lever ( p. 46) Engine number ( p. 32)

  • Page 30: View Of Vehicle, Rear Right Side

    4 VIEW OF VEHICLE View of vehicle, rear right side E01053-10...
  • Page 31 VIEW OF VEHICLE 4 Tool set ( p. 44) Filler cap Light switch ( p. 36) Turn signal switch ( p. 37) Horn button ( p. 38) Ignition/steering lock ( p. 40) Emergency OFF switch ( p. 39) Electric starter button ( p.

  • Page 32: Serial Numbers

    5 SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steer- ing head. 402324-10 Type label The type label USA is located on the right side of the frame. H01128-10...

  • Page 33: Key Number

    SERIAL NUMBERS 5 The type label Canada is located on the left side of the frame. 402381-11 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.

  • Page 34: Engine Number

    5 SERIAL NUMBERS Engine number The engine number is located on the left side of the engine under the engine sprocket. 401949-10 Fork part number The fork part number is stamped on the inner side of the fork stub. 402295-10...

  • Page 35: Shock Absorber Article Number

    SERIAL NUMBERS 5 Shock absorber article number Shock absorber article number is on the left side of the shock absorber. 402382-10...

  • Page 36: Controls

    6 CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. K00347-10 Hand brake lever The hand brake lever is fitted on the right side of the handle- bar.

  • Page 37: Throttle Grip

    CONTROLS 6 Throttle grip The throttle grip is fitted on the right side of the handlebar. K00349-10 Switches on the left side of the handlebar 6.4.1 Combination switch The combination switch is fitted on the left side of the handlebar.

  • Page 38: Light Switch

    6 CONTROLS Overview of the left combination switch Light switch ( p. 36) Menu switch ( p. 37) Turn signal switch ( p. 37) Horn button ( p. 38) V00555-10 6.4.2 Light switch Light switch is fitted on the left side of the handlebar. Possible states Low beam on –...

  • Page 39: Menu Switch

    CONTROLS 6 6.4.3 Menu switch The menu switch is fitted in the middle of the left combination switch. The menu buttons are used to control the display on the combina- tion instrument. Button is the UP button. Button is the DOWN button. Button is the SET button.

  • Page 40: Horn Button

    6 CONTROLS To switch off the turn signal, press the turn signal switch towards the switch housing. 6.4.5 Horn button The horn button is fitted on the left side of the handlebar. Possible states • Horn button in neutral position pressed –...

  • Page 41: Switches On The Right Side Of The Handlebar

    CONTROLS 6 Switches on the right side of the handlebar 6.5.1 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 igni- tion circuit is interrupted, a running engine stops, and the engine cannot be started.

  • Page 42: Ignition/Steering Lock

    6 CONTROLS 6.5.3 Ignition/steering lock The ignition/steering lock is in front of the upper triple clamp. 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 43: Opening The Filler Cap

    CONTROLS 6 Opening the filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –...
  • Page 44 6 CONTROLS Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to enter the groundwater, the soil, or the sewage system. – Lift cover of the filler cap and insert the ignition key in the lock.

  • Page 45: Closing The Filler Cap

    CONTROLS 6 Closing the filler cap – Fold down the filler cap. – Turn the ignition key 90° clockwise. – Push down the filler cap and turn the ignition key counter- clockwise until the lock closes. Warning Fire hazard Fuel is highly flammable, toxic and a health hazard.

  • Page 46: Seat Lock

    6 CONTROLS Seat lock The seat lock is located on the left side of the vehicle. It can be locked with the ignition key. V00043-10 Tool set The tool set is located under the passenger seat. K00414-10...

  • Page 47: Handrails

    CONTROLS 6 6.10 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. K00415-10 6.11 Passenger footrest The passenger footrests are foldable. Possible states Passenger footrest folded in – For operation without a passen- •...

  • Page 48: Shift Lever

    6 CONTROLS 6.12 Shift lever The shift lever is mounted on the left side of the engine. 401950-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11...

  • Page 49: Foot Brake Lever

    CONTROLS 6 6.13 Foot brake lever Foot brake lever is located in front of the right footrest. The rear brake is engaged with the foot brake lever. 402177-10 6.14 Side stand Side stand is located on the left of the vehicle. The side stand is used for parking the motorcycle.
  • Page 50 6 CONTROLS Side stand folded in – This position is mandatory when riding • the motorcycle. The safety starting system is inactive.

  • Page 51: Combination Instrument 7

    COMBINATION INSTRUMENT 7 Combination instrument The combination instrument is attached in front of the handlebar. The combination instrument is divided into 2 function areas. indicator lamps ( p. 50) Display 402644-10...

  • Page 52: Indicator Lamps

    7 COMBINATION INSTRUMENT Indicator lamps 402646-01 The indicator lamps offer additional information about the operating state of the motorcycle. When the ignition is switched on, all indicator lamps light up briefly.
  • Page 53 ABS indicator lamp lights up yellow – Status or error messages relating to ABS. The ABS indi- cator lamp flashes if the ABS mode "SupMot" is enabled. TC indicator lamp lights up yellow – The TC is not available. Contact an authorized KTM work- shop. The TC indicator lamp flashes, if TC actively engages.

  • Page 54: Speed

    7 COMBINATION INSTRUMENT Speed Speed is shown in kilometers per hour km/h or in miles per hour mph. 402647-11 Time The time is shown in area of the display. The time is displayed in 12 hour format if the language is set to EN-US.

  • Page 55: Temperature

    COMBINATION INSTRUMENT 7 Temperature The current ambient temperature is shown in area of the dis- play. 402647-14 Gear display The current gear is shown in area of the display. 402647-10...

  • Page 56: Fuel Tank Capacity

    7 COMBINATION INSTRUMENT Fuel tank capacity The fuel tank contents are shown in area of the display. If the fuel level is getting low, the last segment flashes. Refuel at the next opportunity. 402649-10 Coolant temperature indicator The temperature display consists of 8 bars. The more bars that light up, the hotter the coolant.

  • Page 57: Favorites

    COMBINATION INSTRUMENT 7 "Favorites" – Press the UP or DOWN button until the "Favorites" menu appears on the display. Pressing the SET button opens the menu. – Press the UP or DOWN button to select the menu item and acti- vate it with the SET button.

  • Page 58: Trip 2

    7 COMBINATION INSTRUMENT Press and All entries in the "Trip 1" menu are cleared. hold the but- for 3–5 seconds. 7.11 "Trip 2" – Press the UP or DOWN button until the "Trip 2" menu appears on the display. "Trip 2" shows the distance since the last reset, such as between two refueling stops.

  • Page 59: General Info

    COMBINATION INSTRUMENT 7 7.12 "General info" – Press the UP or DOWN button until the "General Info" menu appears on the display. "Air Temp" displays the ambient air temperature. "Date" displays the date. "ODO" displays the total distance covered. "Battery" displays the battery voltage. "Time"...

  • Page 60: Settings

    7 COMBINATION INSTRUMENT 7.14 "Settings" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the display. Press the SET button to open the menu. Settings for units or various values are made in the "Settings" menu.

  • Page 61: Tc/Abs

    COMBINATION INSTRUMENT 7 7.16 "TC/ABS" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "TC/ABS" menu appears on the display. Press the SET button to open the menu. In the "TC/ABS" menu, "TC" and "ABS" can be switched off. In the "ABS Mode"...

  • Page 62: Shift Light

    7 COMBINATION INSTRUMENT 7.17 "Shift Light" Condition • The vehicle is stationary. • ODO > 1000 km (621 mi). – Press the UP or DOWN button until the "Settings" menu appears on the display. Press the SET button to open the menu. –...
  • Page 63 COMBINATION INSTRUMENT 7 – Press the UP or DOWN button until the "Settings" menu appears on the display. Pressing the SET button opens the menu. – Press the UP or DOWN button until the "Clock-date set" menu is marked on the display. Pressing the SET button again sets the unit of measure.

  • Page 64: Fuel Cons

    7 COMBINATION INSTRUMENT 7.19 "Fuel Cons" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the display. Press the SET button to open the menu. – Press the UP or DOWN button until the "Fuel Cons" menu is marked on the display.

  • Page 65: Distance

    COMBINATION INSTRUMENT 7 7.21 "Distance" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the display. Press the SET button to open the menu. – Press the UP or DOWN button until "Distance" is marked on the display.

  • Page 66: Extra Functions

    7 COMBINATION INSTRUMENT 7.23 "Extra functions" Condition • The vehicle is stationary. – Press the UP or DOWN button until the "Settings" menu appears on the display. Press the SET button to open the menu. – Press the UP or DOWN button until the "Extra functions" menu is marked on the display.
  • Page 67 COMBINATION INSTRUMENT 7 – Press the UP or DOWN button until the "Drive Mode" menu appears on the display. Press the SET button to open the menu. – Use the UP or DOWN button to navigate through the menu. The SET button can be used to select engine and traction control settings that are coordinated with each other.

  • Page 68: Preparing For Use

    Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel. Warning Danger of accidents Non-approved or non-recommended tires and wheels impact the handling character- istic. – Only use tires/wheels approved by KTM with the corresponding speed index.
  • Page 69 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 70: Running In The Engine

    8 PREPARING FOR USE – Get used to handling the motorcycle in a suitable area before making a longer trip. Try also to ride as slowly as possible to get a better feel for the motorcycle. – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. –...
  • Page 71 PREPARING FOR USE 8 Warning Danger of accidents Improper mounting of cases or the tank rucksack impairs the handling characteris- tic. – Mount and secure cases and tank rucksack according to the manufacturer's instructions. Warning Danger of accidents Unstable handling characteristics at high speed. –...
  • Page 72 8 PREPARING FOR USE Warning Danger of accidents Pieces of luggage which have slipped impair the handling characteristic. – Check that your luggage is fixed properly at regular intervals. Warning Fire hazard The hot exhaust system may burn luggage. – Fasten your luggage in such a way that it cannot be burned or singed by the hot exhaust system. –...

  • Page 73: Riding Instructions 9

    RIDING INSTRUCTIONS 9 Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is roadworthy. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 74: Starting The Vehicle

    9 RIDING INSTRUCTIONS Starting the vehicle Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space. Note Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.

  • Page 75: Starting Off

    RIDING INSTRUCTIONS 9 Info Do not press the electric starter button until the combi- nation instrument function check is finished. When starting, DO NOT open the throttle. If you open the throttle during the starting procedure, fuel is not injected by the engine management system and the engine cannot start.

  • Page 76: Shifting, Riding

    9 RIDING INSTRUCTIONS Shifting, riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control. – Avoid abrupt load alterations and sudden braking actions. – Adapt your speed to the road conditions. Warning Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine races.
  • Page 77 RIDING INSTRUCTIONS 9 Warning Risk of injury The passenger may fall from the motorcycle if they conduct themselves incorrectly. – Ensure that the passenger sits correctly on the passenger seat, places his or her feet on the passenger foot rest and holds on to the rider or the grab handles. –...
  • Page 78 9 RIDING INSTRUCTIONS Warning Danger of accidents Total weight and axle loads influence the handling characteristic. The overall weight consists of: motorcycle ready for operation and with a full tank, driver and passenger with protective clothing and helmet, and luggage. – Do not exceed the maximum permissible overall weight or the axle loads.
  • Page 79 Check and, if necessary, correct the coolant level on the cooling system while it is in a cooled state. Info If unusual noises arise during operation, stop immediately, switch off the engine, park the vehicle prop- erly, and contact an authorized KTM workshop. – Shift into a higher gear when conditions allow (incline, road situation, etc.).
  • Page 80 9 RIDING INSTRUCTIONS – After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This will barely reduce the speed but fuel consumption will be considerably lower. – Accelerate only up to a speed suitable for the road surface and weather conditions.

  • Page 81: Engine Braking Control (Msr)

    Warning Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)
  • Page 82 9 RIDING INSTRUCTIONS Warning Danger of accidents The brake system fails in the event of overheating. If the foot brake lever is not released, the brake linings drag continuously. – Take your foot off the foot brake lever when you are not braking. Warning Danger of accidents Higher total weight increases the stopping distance.
  • Page 83 RIDING INSTRUCTIONS 9 Warning Danger of accidents The rear wheel can lock due to the engine braking effect. – Pull in the clutch, if you perform emergency or full braking, or if you brake on a slippery ground. – When braking, release the throttle and apply the front and rear brakes at the same time. Info When ABS is active, you can achieve maximum braking power even on low grip surfaces such as sandy, wet, or slippery terrain without locking of the tires.

  • Page 84: Stopping, Parking

    9 RIDING INSTRUCTIONS Stopping, parking Warning Risk of injury People who act without authorization endanger themselves and others. – Do not leave the vehicle unattended if the engine is running. – Protect the vehicle against access by unauthorized persons. – Lock the steering and remove the ignition key if you leave the vehicle unattended. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated.
  • Page 85 RIDING INSTRUCTIONS 9 Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive. – Allow the vehicle to cool down before covering it. –...

  • Page 86: Transporting

    9 RIDING INSTRUCTIONS Transporting Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive. –...

  • Page 87: Refueling

    RIDING INSTRUCTIONS 9 Refueling Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. – Switch off the engine for refueling.
  • Page 88 In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Improper handling of fuel is a danger to the environment.

  • Page 89: Service Schedule 10

    Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.
  • Page 90 10 SERVICE SCHEDULE Every two years Every year every 20,000 km (12,400 mi) every 10,000 km (6,200 mi) after 1,000 km (620 mi) ○ ● ● ● Check the rear brake fluid level. ( p. 124) ● ● ● Check/correct the fluid level of the hydraulic clutch. ( p.
  • Page 91 Check the CO adjustment using the KTM diagnostics tool. ○ ● ● ● ● Reset the service interval display. ○ ● ● ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ One-time interval ● Periodic interval...

  • Page 92: Recommended Work

    10 SERVICE SCHEDULE 10.3 Recommended work Every four years Every year every 30,000 km (18,600 mi) every 10,000 km (6,200 mi) after 1,000 km (620 mi) ● Check the frame. ● Check the swingarm. ● ● Check the swingarm bearing for play. ●...

  • Page 93: Tuning The Chassis 11

    TUNING THE CHASSIS 11 11.1 Adjusting the spring pretension of the shock absorber Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behav- ior. – Following modifications, ride slowly at first to get the feel of the new ride behavior. Info The spring pretension defines the initial status of the spring operation on the shock absorber.

  • Page 94: Adjusting The Footrests

    11 TUNING THE CHASSIS 11.2 Adjusting the footrests Info The operations on the footrest brackets are the same for the left and right sides. – Remove lock ring – Remove the pin of the rider footrest. Take off the rider footrest with the spring.
  • Page 95 TUNING THE CHASSIS 11 – Adjust the footrest bracket to the desired position. V00051-01 – Mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) Loctite 243™ ® footrest bracket V00045-10...
  • Page 96 11 TUNING THE CHASSIS – Mount the rider footrest with the spring and pin. H00385-01 – Mount lock ring V00562-10...

  • Page 97: Service Work On The Chassis 12

    SERVICE WORK ON THE CHASSIS 12 12.1 Raising the motorcycle with the rear lifting gear Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Mount the supports of the lifting gear. –...

  • Page 98: Lifting The Motorcycle With The Front Lifting Gear

    12 SERVICE WORK ON THE CHASSIS – Secure the motorcycle against falling over. – Remove the rear lifting gear and lean the vehicle on side stand 402029-10 12.3 Lifting the motorcycle with the front lifting gear Note Danger of damage The parked vehicle can roll away or fall over. –...

  • Page 99: Taking The Motorcycle Off The Front Lifting Gear

    SERVICE WORK ON THE CHASSIS 12 Main work – Move the handlebar to the straight-ahead position. Attach the lifting gear to the steering stem. Mounting pin (69329965030) Front wheel work stand, large (69329965000) Info Always raise the motorcycle at the rear first. 402345-01 –...

  • Page 100: Removing The Passenger Seat

    12 SERVICE WORK ON THE CHASSIS – Secure the motorcycle against falling over. – Remove the front lifting gear. 312029-10 12.5 Removing the passenger seat – Insert the ignition key in seat lock and turn it clockwise. – Raise the rear of the passenger seat, push it towards the rear, and remove it upward.

  • Page 101: Mounting The Passenger Seat

    SERVICE WORK ON THE CHASSIS 12 12.6 Mounting the passenger seat – Hook catches of the passenger seat onto the storage com- partment, lower the rear, and simultaneously push forward. – Press down the passenger seat until it clicks into place. Warning Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly.

  • Page 102: Checking The Chain For Dirt

    12 SERVICE WORK ON THE CHASSIS 12.7 Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 100) 400678-01 12.8 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. –...
  • Page 103 SERVICE WORK ON THE CHASSIS 12 Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info The service life of the chain depends largely on its maintenance. Preparatory work –...

  • Page 104: Checking The Chain Tension

    12 SERVICE WORK ON THE CHASSIS 12.9 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.
  • Page 105 SERVICE WORK ON THE CHASSIS 12 Main work – Shift gear to neutral. – Push the chain upwards near the vertical rib of the swingarm and measure the chain tension Info The upper chain section must be taut. Chain wear is not always even. Repeat this measure- ment at different chain positions.

  • Page 106: Adjusting The Chain Tension

    12 SERVICE WORK ON THE CHASSIS 12.10 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.
  • Page 107 SERVICE WORK ON THE CHASSIS 12 Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 5 mm (0.2 in) Turn the adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks...

  • Page 108: Checking The Chain, Rear Sprocket, And Engine Sprocket

    12 SERVICE WORK ON THE CHASSIS Finishing work – Check the chain tension. ( p. 102) – Remove the rear of the motorcycle from the lifting gear. p. 95) 12.11 Checking the chain, rear sprocket, and engine sprocket Preparatory work –...
  • Page 109 SERVICE WORK ON THE CHASSIS 12 – Shift gear to neutral. – Pull the lower chain section with the specified weight Guideline Weight of chain wear mea- 15 kg (33 lb.) surement – Measure distance of 18 chain rollers in the lower chain section.

  • Page 110: Adjusting The Basic Position Of The Clutch Lever

    12 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If in area by the chain sliding guard screw is visi- ble from above: – Replace the chain sliding guard. – Check that the chain sliding guard is firmly seated. »...

  • Page 111: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS 12 – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw K00354-10 12.13 Checking/correcting the fluid level of the hydraulic clutch Warning Skin irritation Brake fluid causes skin irritation. –...
  • Page 112 12 SERVICE WORK ON THE CHASSIS Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info The fluid level rises with increasing wear of the clutch facing discs. Never use DOT 5 brake fluid.
  • Page 113 SERVICE WORK ON THE CHASSIS 12 – Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilled brake fluid immediately with water.

  • Page 114: Brake System

    Do not make any changes to the suspension travel. – Only use spare parts on the brake system which have been approved and recommended by KTM. – Only use tires/wheels approved by KTM with the corre- sponding speed index. – Maintain the specified tire air pressure. –...
  • Page 115 BRAKE SYSTEM 13 Warning Danger of accidents Driving aids can only prevent a rollover within the physical limitations. It is not always possible to compensate for extreme riding situations, for example with luggage loaded with a high center of gravity, varying road surfaces, steep descents or full braking without disengaging the gear.

  • Page 116: Adjusting The Basic Position Of The Hand Brake Lever

    13 BRAKE SYSTEM ditions, for example when making "wheelies" or if the rear wheel spins. This causes the ABS to switch off. To reactivate the ABS, the vehicle must be stopped and the ignition switched off. The ABS is reactivated when the vehicle is switched on again.

  • Page 117: Checking The Brake Discs

    Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the front and rear brake disc thickness at multiple...

  • Page 118: Checking The Brake Fluid Level Of The Front Brake

    KTM workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)

  • Page 119: Adding Front Brake Fluid

    If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)
  • Page 120 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 121 BRAKE SYSTEM 13 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. Only use clean brake fluid from a sealed container.

  • Page 122: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Damaged brake discs reduce the braking effect.

  • Page 123: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 13 – Check the brake linings for minimum thickness ≥ 1 mm (≥ 0.04 in) Minimum thickness » If the minimum thickness is less than specified: – Change the front brake linings. – Check the brake linings for damage and cracking. »...

  • Page 124: Adjusting The Basic Position Of The Foot Brake Lever

    13 BRAKE SYSTEM – Disconnect spring – 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) »...
  • Page 125 BRAKE SYSTEM 13 – Disconnect spring – Remove screw – Loosen nut and turn it back with ball joint until the maximum amount of free travel is reached. – To adjust the basic position of the foot brake lever to individ- ual requirements, loosen nut and turn screw accord-...

  • Page 126: Checking Rear Brake Fluid Level

    KTM workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)

  • Page 127: Adding Rear Brake Fluid

    If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)
  • Page 128 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 129 BRAKE SYSTEM 13 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. Only use clean brake fluid from a sealed container.

  • Page 130: Checking The Rear Brake Linings

    Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Damaged brake discs reduce the braking effect.

  • Page 131: Wheels, Tires 14

    WHEELS, TIRES 14 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear lifting gear. ( p. 95) – Lift the motorcycle with the front lifting gear. ( p. 96) Main work – Remove screw and pull wheel speed sensor out of the hole.
  • Page 132 14 WHEELS, TIRES – Loosen screw by several rotations. – Loosen screws – Press on screw to push the wheel spindle out of the axle clamp. – Remove screw Warning Danger of accidents Reduced braking effect caused by 602546-10 damaged brake discs. –...

  • Page 133: Installing The Front Wheel

    WHEELS, TIRES 14 14.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –...
  • Page 134 14 WHEELS, TIRES – Clean screw and wheel spindle – Grease wheel spindle lightly. Long-life grease ( p. 234) – Jack up the front wheel into the fork, position it, and insert the wheel spindle. Info The arrow on the rim, near the hub, shows the direction K00430-10 of travel.
  • Page 135 WHEELS, TIRES 14 – Position wheel speed sensor in the drill hole. Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position the brake caliper. The brake linings are correctly positioned. – Position spacers . Mount screws but do not tighten yet.

  • Page 136: Removing The Rear Wheel

    14 WHEELS, TIRES – Remove the rear of the motorcycle from the lifting gear. p. 95) – Operate the front brake and compress the fork a few times firmly. The fork legs straighten. – Tighten screws Guideline Screw, fork stub 15 Nm (11.1 lbf ft) K00434-10 14.3...
  • Page 137 WHEELS, TIRES 14 Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake piston. – Remove screw and pull wheel speed sensor out of the hole. – Remove nut . Remove chain adjuster E01042-10 –...
  • Page 138 14 WHEELS, TIRES – Push the rear wheel forward as far as possible. Remove the chain from the rear sprocket. Info Cover the components to protect them against damage. – Hold the rear wheel and remove the wheel spindle. – Pull the rear wheel back until the brake caliper support is sus- pended freely between the brake disc and rim.

  • Page 139: Installing The Rear Wheel

    WHEELS, TIRES 14 14.4 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Warning Danger of accidents There is no braking effect to start with at the rear brake after installing the rear wheel.
  • Page 140 14 WHEELS, TIRES – Clean and grease the thread of the wheel spindle and nut. Long-life grease ( p. 234) – Clean and grease the wheel spindle. Long-life grease ( p. 234) – Clean the contact areas of the brake caliper support and swingarm.
  • Page 141 WHEELS, TIRES 14 – Engage the thurst bearing of brake caliper support and the swingarm. – Lift the rear wheel into the swingarm, position it, and insert the wheel spindle. The brake linings are correctly positioned. – Place the chain on the sprocket. –...

  • Page 142: Checking The Rear Hub Rubber Dampers

    14 WHEELS, TIRES Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Operate the foot brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure point. Finishing work – Check the chain tension.
  • Page 143 WHEELS, TIRES 14 Main work – Check bearing » If the bearing is damaged or worn: – Change the bearing of the rear sprocket carrier. – Check rubber dampers of the rear hub for damage and wear. » If the rubber dampers of the rear hub are damaged or worn: –...
  • Page 144 14 WHEELS, TIRES – Lay the rear wheel on a workbench with the rear sprocket fac- ing upwards and insert the wheel spindle in the hub. – To check play , hold the rear wheel tight and try to turn the rear sprocket with your hand.

  • Page 145: Checking The Tire Condition

    Warning Danger of accidents If a tire bursts while riding, the vehicle becomes uncontrollable. – Ensure that damaged or worn tires are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling charac- teristic.
  • Page 146 14 WHEELS, TIRES Info The type, condition, and air pressure of the tires all have a major impact on the handling of the motorcy- cle. Worn tires have a negative effect on handling characteristics, especially on wet surfaces. – Check the front and rear tires for cuts, run-in objects, and other damage.

  • Page 147: Checking The Tire Pressure

    DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. KTM recommends that the tires be changed after 5 H01144-10 years at the latest, regardless of the actual state of wear.
  • Page 148 14 WHEELS, TIRES – Remove the protection cap. – Check the tire pressure when the tires are cold. Tire air pressure, solo front 2.0 bar (29 psi) rear 2.0 bar (29 psi) Tire air pressure with passenger / fully loaded front 2.0 bar (29 psi) 400695-01...

  • Page 149: Electrical System 15

    ELECTRICAL SYSTEM 15 15.1 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 safety glasses. – Avoid contact with battery acid and battery gases. –...
  • Page 150 15 ELECTRICAL SYSTEM Main work – Disconnect negative cable from the battery. V00580-10...
  • Page 151 ELECTRICAL SYSTEM 15 – Remove positive terminal cover – Disconnect both positive cables from the battery. – Detach rubber band – Pull the battery up and out of the battery holder. V00578-10...

  • Page 152: Installing The Battery

    15 ELECTRICAL SYSTEM 15.2 Installing the battery Main work – Position the battery in the battery holder. Alternative 1 Battery (YTX9-BS) ( p. 222) Alternative 2 Battery (HTZ12A-BS) ( p. 222) The battery terminals face opposite the direction of travel. –...
  • Page 153 ELECTRICAL SYSTEM 15 – Connect negative cable to the battery. Guideline Screw, battery termi- 2 Nm (1.5 lbf ft) V00580-11 Finishing work – Mount the passenger seat. ( p. 99) – Set the time and date. ( p. 60)

  • Page 154: Recharging The Battery

    15 ELECTRICAL SYSTEM 15.3 Recharging 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 safety glasses. – Avoid contact with battery acid and battery gases. –...
  • Page 155 ELECTRICAL SYSTEM 15 Info Even when there is no load on the battery, it discharges 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 service life of the battery. If the charging current, charging voltage, or charging time is exceeded, electrolyte escapes through the safety valves.
  • Page 156 15 ELECTRICAL SYSTEM Main work – Connect the battery charger to the battery. Switch on the bat- tery charger. Battery charger (58429074000) You can also use the battery charger to test the open-circuit voltage and start potential of the battery, and to test the alter- nator.

  • Page 157: Changing The Main Fuse

    ELECTRICAL SYSTEM 15 15.4 Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. The main fuse is under the passenger seat. Preparatory work –...
  • Page 158 15 ELECTRICAL SYSTEM Main work – Remove protection caps V00581-10 – Remove the faulty main fuse Info A defective fuse is indicated by a burned-out fuse wire A spare fuse is located in the starter relay. – Install a new main fuse. Fuse (58011109130) ( p.

  • Page 159: Changing The Abs Fuses

    ELECTRICAL SYSTEM 15 – Mount protection caps V00581-10 Finishing work – Mount the passenger seat. ( p. 99) – Set the time and date. ( p. 60) 15.5 Changing the ABS fuses Warning Fire hazard Incorrect fuses overload the electrical system. –...
  • Page 160 15 ELECTRICAL SYSTEM Info Two fuses for the ABS are located under the passenger seat. These fuses protect the return pump and the hydraulic unit of the ABS. The third fuse, which protects the ABS control unit, is located in the fuse box. Preparatory work –...

  • Page 161: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM 15 To change the fuse of the ABS return pump: – Remove the protection cap and fuse – Insert a new fuse. Fuse (58011109125) ( p. 222) – Mount the protection cap. V00583-10 Finishing work – Mount the passenger seat. ( p.
  • Page 162 15 ELECTRICAL SYSTEM Main work – Remove screw – Remove the trim. V00084-10 – Open fuse box cover K00365-10...
  • Page 163 ELECTRICAL SYSTEM 15 – Remove the defective fuse. Guideline Fuse 1 - 10 A - ignition, combination instrument, engine electronics control unit, alarm system (optional), turn signal Fuse 2 - 10 A - ignition, engine electronics control unit Fuse 3 - 10 A - fuel pump Fuse 4 - 10 A - radiator fan Fuse 5 - 10 A - horn, brake light K00366-10...
  • Page 164 15 ELECTRICAL SYSTEM Warning Fire hazard Incorrect fuses overload the electrical sys- tem. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. – Use spare fuses with the correct rating only. Fuse (75011088010) ( p.

  • Page 165: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 15 – Position the trim. – Mount and tighten screw Guideline Screw, fuel spoiler 3 Nm (2.2 lbf ft) V00084-10 15.7 Removing the headlight mask with the headlight – Switch off the ignition by turning the ignition key to the posi- tion –...

  • Page 166: Installing The Headlight Mask With The Headlight

    15 ELECTRICAL SYSTEM – Fold the headlight mask forward. – Disconnect plug-in connectors – Take off the headlight mask. V00075-10 15.8 Installing the headlight mask with the headlight Main work – Connect plug-in connectors V00075-11...

  • Page 167: Changing The Headlight Bulb

    ELECTRICAL SYSTEM 15 – Position the headlight mask. – Mount and tighten screws Guideline Screw, headlight EJOT 2 Nm (1.5 lbf ft) – Mount and tighten screws Guideline Remaining screws, 5 Nm (3.7 lbf ft) chassis K00439-11 – Check that the lighting is functioning properly. Finishing work –...
  • Page 168 15 ELECTRICAL SYSTEM Main work – Unplug connector – Remove protection cap V00064-10 – Detach retaining clamp – Remove bulb – Position the new bulb in the headlight housing. Headlight (H4 / socket P43t) ( p. 222) Tabs engage in the recesses. –...

  • Page 169: Changing The Parking Light Bulb

    ELECTRICAL SYSTEM 15 – Mount protection cap – Plug in connector V00064-10 Finishing work – Install the headlight mask with the headlight. ( p. 164) – Check the headlight setting. ( p. 170) 15.10 Changing the parking light bulb Note Damage to reflector Grease on the reflector reduces the brightness.

  • Page 170: Changing The Turn Signal Bulb

    15 ELECTRICAL SYSTEM Main work – Pull cable sleeve and the socket of parking light care- fully out of the housing. – Remove the bulb. – Position a new light bulb in the socket. Parking light (W5W / socket W2.1x9.5d) ( p.
  • Page 171 ELECTRICAL SYSTEM 15 – Remove the screw on the rear of the turn signal housing. – Remove turn signal glass – Press the bulb carefully into the socket, turn it counterclock- wise by about 30°, and pull it out of the socket. Info Do not touch the reflector with your fingers and keep it free from grease.

  • Page 172: Checking The Headlight Setting

    15 ELECTRICAL SYSTEM 15.12 Checking the headlight setting – Position 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 173: Adjusting The Headlight Range

    ELECTRICAL SYSTEM 15 15.13 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 170) Main work – Adjust the beam distance of the headlight by turning screw Guideline For a motorcycle with rider, and with luggage and a passen- ger if applicable, the light/dark boundary must be exactly on the lower mark (applied in: Checking the headlight setting).

  • Page 174: Diagnostics Connector

    15 ELECTRICAL SYSTEM 15.14 Diagnostics connector Diagnostics connector is located under the front rider's seat. H00932-11...

  • Page 175: Cooling System 16

    COOLING SYSTEM 16 16.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . Heat expansion causes excess coolant to flow into compensating tank .

  • Page 176: Checking The Antifreeze And Coolant Level

    16 COOLING SYSTEM 16.2 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
  • Page 177 COOLING SYSTEM 16 Main work – Remove radiator cap and cap of the compensating tank. – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: –...

  • Page 178: Checking The Coolant Level In The Compensating Tank

    16 COOLING SYSTEM The radiator must be filled completely. » If the coolant level does not match the specified value: – Check the coolant level and the reason for the loss. Coolant ( p. 230) » If you had to add more coolant than the specified amount: >...
  • Page 179 COOLING SYSTEM 16 Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...

  • Page 180: Draining The Coolant

    16 COOLING SYSTEM » If there is no coolant in the compensating tank: – Check the cooling system for leaks. Info Do not start up the motorcycle! – Fill/bleed the cooling system. p. 180) 16.4 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. –...
  • Page 181 COOLING SYSTEM 16 Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...

  • Page 182: Filling/Bleeding The Cooling System

    16 COOLING SYSTEM 16.5 Filling/bleeding the cooling system Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. –...
  • Page 183 COOLING SYSTEM 16 – Remove bleeder screw – Tilt the vehicle slightly to the right. – Pour in coolant until it emerges without bubbles at the vent hole, and then mount and tighten bleeder screw immedi- ately. Coolant 1.20 l Coolant ( p.

  • Page 184: Changing The Coolant

    16 COOLING SYSTEM – When the engine is cool, check the coolant level in the radiator and, if necessary, add coolant. – Check the coolant level in the compensating tank. ( p. 176) 16.6 Changing the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. –...
  • Page 185 COOLING SYSTEM 16 – Position the motorcycle upright. – Place a suitable container under the engine. – Remove screw K00379-10 – Remove radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Plug, drain hole of M10x1 15 Nm (11.1 lbf ft)
  • Page 186 16 COOLING SYSTEM – Remove bleeder screw – Tilt the vehicle slightly to the right. – Pour in coolant until it emerges without bubbles at the vent hole, and then mount and tighten bleeder screw immedi- ately. Coolant 1.20 l Coolant ( p.
  • Page 187 COOLING SYSTEM 16 – When the engine is cool, check the coolant level in the radiator and, if necessary, add coolant. – Check the coolant level in the compensating tank. ( p. 176)

  • Page 188: Tuning The Engine

    17 TUNING THE ENGINE 17.1 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. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load. –...

  • Page 189: Adjusting The Basic Position Of The Shift Lever

    TUNING THE ENGINE 17 17.2 Adjusting the basic position of the shift lever – Remove screw with the washers and take off shift lever H01081-10 – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing.

  • Page 190: Drive Mode (Optional)

    17 TUNING THE ENGINE 17.3 Drive Mode (optional) Possible states SPORT – Homologated performance with very direct response; • the traction control allows greater slip on the rear wheel STREET – Homologated performance with balanced response; • the traction control allows normal slip on the rear wheel RAIN –...

  • Page 191: Traction Control (Optional) (Tc)

    TUNING THE ENGINE 17 17.4 Traction control (optional) (TC) The traction control (TC ( p. 189)) lowers the engine torque in case of loss of traction in the rear wheel. Depending on the trac- tion control setting, a slight slip on the rear wheel may be desir- able.

  • Page 192: Service Work On The Engine

    18 SERVICE WORK ON THE ENGINE 18.1 Checking the engine oil level Info The engine oil level must be checked at normal engine operating temperature. – Stand the motorcycle upright on a horizontal surface. – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level.

  • Page 193: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens

    SERVICE WORK ON THE ENGINE 18 18.2 Changing the engine oil and oil filter, cleaning the oil screens Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden. – Wear suitable protective clothing and safety gloves. –...
  • Page 194 18 SERVICE WORK ON THE ENGINE Main work – Rest the motorcycle on its side stand on a horizontal surface. – Place a suitable container under the engine. – Remove oil filler plug with the O-ring from the clutch cover. H01066-10 –...
  • Page 195 SERVICE WORK ON THE ENGINE 18 – Remove screws . Remove oil filter cover with the O- ring. – Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) – Thoroughly clean the parts and sealing surface. K00371-10 –...
  • Page 196 18 SERVICE WORK ON THE ENGINE – Insert the new oil filter. – Oil the O-rings of the oil filter covers. Position oil filter cover – Mount and tighten the screws. Guideline Screw, oil filter cover 6 Nm (4.4 lbf ft) K00372-10 –...
  • Page 197 SERVICE WORK ON THE ENGINE 18 – Remove screw plug with oil screen and the O-rings. – Completely drain the remaining engine oil. – Thoroughly clean the parts and sealing surface. H00382-10 – Position oil screen with the O-rings on a pin wrench. –...
  • Page 198 18 SERVICE WORK ON THE ENGINE – Mount and tighten screw plug with the O-ring. Guideline Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) K00370-11 – Position the oil screen with the O-rings. – Mount and tighten screw plug with the O-ring.

  • Page 199: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 18 – Mount and tighten oil filler plug with the O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine.
  • Page 200 18 SERVICE WORK ON THE ENGINE Main work – Remove filler plug and the O-ring from the clutch cover, and fill up with engine oil. Engine oil (SAE 10W/60) (00062010035) ( p. 231) Engine oil (SAE 10W/50) ( p. 232) Info In order to achieve optimal engine performance, it is H01066-10...
  • Page 201 SERVICE WORK ON THE ENGINE 18 Finishing work – Check the engine oil level. ( p. 190)

  • Page 202: Cleaning, Care

    19 CLEANING, CARE 19.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...
  • Page 203 CLEANING, CARE 19 – Seal the exhaust system to keep water out. – First remove coarse dirt particles with a gentle spray of water. – Spray very dirty areas with a normal motorcycle cleaner and then clean with a brush. Motorcycle cleaner ( p.
  • Page 204 19 CLEANING, CARE – After cleaning, ride the vehicle a short distance until the engine warms up. Info The heat produced causes water at inaccessible loca- tions in the engine and on the brake system to evapo- rate. – After the motorcycle has cooled off, lubricate all moving parts and bearings.

  • Page 205: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE 19 Special cleaner for glossy and matte paint finishes, metal and plastic surfaces ( p. 235) – Lubricate the ignition/steering lock. Universal oil spray ( p. 235) 19.2 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 precau- tions against aggressive road salt.
  • Page 206 19 CLEANING, CARE – Treat the engine, the swingarm, and all other bare or galvanized parts (except brake discs) with a wax-based anti-corrosion substance. Info To prevent serious reduction of the braking efficiency, make sure no anti-corrosion substance gets on to the brake discs.

  • Page 207: Storage 20

    STORAGE 20 20.1 Storage Info If you want to garage the motorcycle for a longer period, take the following actions. Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season.
  • Page 208 20 STORAGE – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear lifting gear. ( p. 95) – Lift the motorcycle with the front lifting gear. ( p.

  • Page 209: Preparing For Use After Storage

    STORAGE 20 20.2 Preparing for use after storage – Take the motorcycle off the front lifting gear. ( p. 97) – Remove the rear of the motorcycle from the lifting gear. p. 95) – Recharge the battery. p. 152) – Install the battery.

  • Page 210: Troubleshooting

    ( p. 159) – The plug-in connection of the Connect the plug-in connection of the fuel hose connection is not fuel line. connected – Defect in fuel injection system Read out the fault memory using the KTM diagnostics tool.
  • Page 211 Fuel filter is very dirty Check the fuel pressure. – Defect in fuel injection system Read out the fault memory using the KTM diagnostics tool. – Engine overheats Too little coolant in cooling sys- Check the cooling system for leakage.
  • Page 212 – Malfunction in ABS Read out the ABS fault memory using the KTM diagnostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary.
  • Page 213 TROUBLESHOOTING 21 Faults Possible cause Action – Turn signal, brake light, and Fuse 5 blown Change the fuses of individual power horn are not functional consumers. ( p. 159) – Time is not (correctly) dis- Fuse 1 blown Change the fuses of individual power played consumers.

  • Page 214: Technical Data

    22 TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 692.7 cm³ (42.271 cu in) Stroke 80 mm (3.15 in) Bore 105 mm (4.13 in) Compression ratio 12.7:1 Control OHC, intake with cam levers, exhaust controlled by rocker arm, chain drive Valve diameter, intake 42 mm (1.65 in) Valve diameter, exhaust...
  • Page 215 TECHNICAL DATA 22 Primary transmission 36:79 Clutch APTC™ antihopping clutch in oil bath/hydraulically operated Transmission 6-gear, claw shifted Transmission ratio 1st gear 14:35 2nd gear 16:28 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...

  • Page 216: Engine Tightening Torques

    22 TECHNICAL DATA Starting aid Electric starter, automatic decompressor 22.2 Engine tightening torques Screw, membrane fixation 2 Nm (1.5 lbf ft) Loctite ® 243™ Hose clamp, intake flange 2.5 Nm (1.84 lbf ft) Oil nozzle for clutch lubrication 2 Nm (1.5 lbf ft) Oil nozzle for conrod bearing lubri- 2 Nm (1.5 lbf ft) Loctite...
  • Page 217 TECHNICAL DATA 22 Screw, oil pump cover 6 Nm (4.4 lbf ft) Loctite ® 243™ Chain securing guide 5 Nm (3.7 lbf ft) Remaining screws, engine 10 Nm (7.4 lbf ft) Screw in alternator cover 10 Nm (7.4 lbf ft) Screw, alternator cover M6x30 10 Nm (7.4 lbf ft)
  • Page 218 22 TECHNICAL DATA Screw, ignition coil 10 Nm (7.4 lbf ft) Screw, ignition pulse generator 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, locking lever 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, resonator 10 Nm (7.4 lbf ft) Loctite ®...
  • Page 219 TECHNICAL DATA 22 Screw, water pump wheel 10 Nm (7.4 lbf ft) Loctite ® 243™ Screws, SAS cover M6x12 10 Nm (7.4 lbf ft) Loctite ® 243™ Intake channel vacuum connection M6x0.75 2.5 Nm (1.84 lbf ft) Loctite ® 243™ Oil jet, piston cooling M6x0.75 4 Nm (3 lbf ft)
  • Page 220 22 TECHNICAL DATA Cylinder head screw Tightening sequence: Tighten diagonally, beginning with the rear screw on the timing chain shaft. Step 1 15 Nm (11.1 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 45 Nm (33.2 lbf ft) Step 4 60 Nm (44.3 lbf ft) Lubricated with engine oil...
  • Page 221 TECHNICAL DATA 22 Coolant temperature sensor on M12x1.5 12 Nm (8.9 lbf ft) cylinder head Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) Oil pressure regulator valve plug M12x1.5 20 Nm (14.8 lbf ft) Screw plug, oil channel M14x1.5 15 Nm (11.1 lbf ft) Loctite...

  • Page 222: Capacities

    22 TECHNICAL DATA 22.3 Capacities 22.3.1 Engine oil Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60) (00062010035) ( p. 231) Engine oil Engine oil (SAE 10W/50) Alternative engine oil p. 232) 22.3.2 Coolant Coolant 1.20 l (1.27 qt.) Coolant ( p.
  • Page 223 TECHNICAL DATA 22 Suspension travel front 135 mm (5.31 in) rear 135 mm (5.31 in) Brake system front Disc brake with radially mounted four-piston brake caliper, floating brake disc rear Disc brake with single-pot brake caliper, floating Brake discs - diameter front 320 mm (12.6 in) rear...

  • Page 224: Electrical System

    22 TECHNICAL DATA Wheelbase 1,466 ± 15 mm (57.72 ± 0.59 in) Seat height unloaded 835 mm (32.87 in) Ground clearance unloaded 192 mm (7.56 in) Weight without fuel, approx. 152.5 kg (336.2 lb.) Maximum permissible front axle load 150 kg (331 lb.) Maximum permissible rear axle load 220 kg (485 lb.) Maximum permissible overall weight...

  • Page 225: Tires

    160/60 ZR 17 M/C 69W TL Metzeler SPORTEC M7 RR Metzeler SPORTEC M7 RR The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork Fork part number 05.18.7L.19...

  • Page 226: Shock Absorber

    22 TECHNICAL DATA Fork length 816 mm (32.13 in) Fork oil per fork leg 480 ml (16.23 fl. oz.) Fork oil (SAE 4) (48601166S1) p. 232) 22.8 Shock absorber Shock absorber article number 01.18.7N.19 Shock absorber WP Performance Systems emulsion with Pro‑Lever link- Spring preload Standard 4 clicks...
  • Page 227 TECHNICAL DATA 22 SAS valve screw on frame 4 Nm (3 lbf ft) Screw, air filter box 3 Nm (2.2 lbf ft) Screw, cable on starter motor 3 Nm (2.2 lbf ft) Screw, combination instrument 4 Nm (3 lbf ft) Screw, combination switch, left 1.5 Nm (1.11 lbf ft) Screw, combination switch, right...
  • Page 228 22 TECHNICAL DATA Screw, ball joint of push rod on 10 Nm (7.4 lbf ft) Loctite ® 243™ foot brake cylinder Screw, battery terminal 2 Nm (1.5 lbf ft) Screw, brake assembly 5 Nm (3.7 lbf ft) Screw, brake fluid reservoir of rear 5 Nm (3.7 lbf ft) brake Screw, chain guard...
  • Page 229 TECHNICAL DATA 22 Screw, tail light cover 8 Nm (5.9 lbf ft) Screw, voltage regulator 8 Nm (5.9 lbf ft) Screw, wheel speed sensor 6 Nm (4.4 lbf ft) Nut, manifold on cylinder head 20 Nm (14.8 lbf ft) Copper paste Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite...
  • Page 230 22 TECHNICAL DATA Screw, handrail, cover M8x20 18 Nm (13.3 lbf ft) Loctite ® 243™ Screw, ignition lock (tamper-proof Loctite ® 243™ screw) Screw, license plate holder 18 Nm (13.3 lbf ft) Loctite ® 243™ Screw, linkage bracket, front 25 Nm (18.4 lbf ft) Loctite ®...
  • Page 231 TECHNICAL DATA 22 Screw, side stand 35 Nm (25.8 lbf ft) Loctite ® 243™ Screw, subframe 45 Nm (33.2 lbf ft) Loctite ® 243™ Banjo bolt, brake line M10x1 25 Nm (18.4 lbf ft) Screw, bottom shock absorber M10x1.25 50 Nm (36.9 lbf ft) Loctite ®...

  • Page 232: Substances

    23 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 – REACT PERFORMANCE DOT 4 Motorex ®...
  • Page 233 JASO T903 MA ( p. 236) – SAE ( p. 236) (SAE 10W/60) – KTM LC4 2007+ Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Synthetic engine oil...
  • Page 234 23 SUBSTANCES Engine oil (SAE 10W/50) Standard/classification – JASO T903 MA ( p. 236) – SAE ( p. 236) (SAE 10W/50) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties.
  • Page 235 SUBSTANCES 23 – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).

  • Page 236: Auxiliary Substances

    24 AUXILIARY SUBSTANCES Chain cleaner Recommended supplier Motorex ® – Chain Clean Chain lube for road use Guideline Recommended supplier Motorex ® – Chainlube Road Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Long-life grease Recommended supplier Motorex ® –...
  • Page 237 AUXILIARY SUBSTANCES 24 Motorcycle cleaner Recommended supplier Motorex ® – Moto Clean Perfect Finish and high gloss polish for paints Recommended supplier Motorex ® – Moto Polish & Shine Preserving materials for paints, metal and rubber Recommended supplier Motorex ® –...

  • Page 238: Standards

    25 STANDARDS JASO T903 MA Different technical development directions required a separate specification for motorcycles – the JASO T903 MA standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 239: Index Of Special Terms 26

    INDEX OF SPECIAL TERMS 26 Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces Motor Slip Regulation Auxiliary function of the motor control, which pre- vents rear wheel locking with excessive engine braking effect, by lightly opening the throttle valve On-board diagnosis Vehicle system, which monitors the specified parame-...

  • Page 240: List Of Abbreviations

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

  • Page 241: List Of Symbols 28

    ABS indicator lamp lights up yellow – Status or error messages relating to ABS. The ABS indi- cator lamp flashes if the ABS mode "SupMot" is enabled. TC indicator lamp lights up yellow – The TC is not available. Contact an authorized KTM work- shop. The TC indicator lamp flashes, if TC actively engages.

  • Page 242: Green And Blue Symbols

    28 LIST OF SYMBOLS 28.3 Green and blue symbols Green and blue symbols reflect information. The turn signal indicator lamp flashes green simultaneously with the turn signal – The turn signal is switched on. The idle indicator lamp lights up green – The transmission is in idle. The high beam indicator lamp lights up blue –...

  • Page 243: Index

    INDEX rear brake, checking ....128 INDEX Brake system ..... . 112-128 ABS .
  • Page 244 INDEX coolant temperature indicator ... . 54 Combination switch ..... . 35 "Distance"...
  • Page 245 INDEX Engine oil level checking ......190 Hand brake lever ..... . . 34 Engine sprocket basic position, adjusting .
  • Page 246 INDEX Loading the vehicle ..... . 68 Parking light bulb Luggage ......68 changing .
  • Page 247 INDEX Riding starting off ......73 TC ....... . 189 Technical data Safe operation .
  • Page 248 INDEX Turn signal bulb changing ......168 Turn signal switch ..... . . 37 Type label .
  • Page 249 *3213748en* 3213748en 08/2017 KTM Sportmotorcycle GmbH Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com...

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