KTM 690 Enduro R 2021 Owner's Manual
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KTM 690 Enduro R 2021 Owner's Manual

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OWNER'S MANUAL
2021
690 ENDURO R
Art. no. 3214279en

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Summary of Contents for KTM 690 Enduro R 2021

  • Page 1 OWNER'S MANUAL 2021 690 ENDURO R Art. no. 3214279en...
  • Page 3 KTM accepts no liability for delivery options, deviations from fig- ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 6.16 Shift lever ........18 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 6.17 Foot brake lever ....... 19 Symbols used ........5 6.18 Side stand........19 Formats used........5 6.19 Opening the fuel tank filler cap ..19 SAFETY ADVICE..........
  • Page 5 TABLE OF CONTENTS 10.2 Adjusting the compression damping 12 BRAKE SYSTEM ......... 63 of the fork ........42 12.1 Anti-lock braking system (ABS) ..63 10.3 Adjusting the rebound damping of 12.2 Adjusting the basic position of the the fork........... 43 hand brake lever ......
  • Page 6 TABLE OF CONTENTS 15.3 Checking the coolant level ....95 27.3 Green and blue symbols....129 15.4 Draining the coolant ..... 96 INDEX ............. 130 15.5 Filling/bleeding the cooling system ........97 15.6 Changing the coolant ....98 16 TUNING THE ENGINE....... 100 16.1 Changing the riding mode ....

  • Page 7: Means Of Representation 1

    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 8: Safety Advice

    Info This vehicle is only authorized for operation on public roads in its homologated version. When used in a dusty environment, it may be necessary to use air filter protection. Your authorized KTM dealer will be happy to advise you.

  • Page 9: Tampering Warning

    An appropriate driver's license is needed to drive 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 10: Protective Clothing

    The Owner's Manual can be downloaded several times using the QR code or the link on the delivery certificate. The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. A printed copy can also be ordered from your authorized KTM dealer.

  • Page 11: Important Notes 3

    Manufacturer warranty, implied warranty The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con- firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

  • Page 12: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) S04589-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Fuel tank filler cap Seat release ( p. 18) Side stand ( p. 19) Compression damping of the shock absorber ( p.

  • Page 13: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) S04590-10 Ignition and steering lock ( p. 17) Fork compression adjuster Light switch ( p. 15) Turn signal switch ( p. 15) Horn button ( p. 14) Combination switch ( p.

  • Page 14: Serial Numbers

    5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Type label The Europe type label is located on the right side of the frame. The Australia type label is located on the left side of the frame.

  • Page 15: Engine Number

    SERIAL NUMBERS 5 Engine number The engine number is stamped 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. 401947-10 Shock absorber article number The shock absorber article number is on the left side of the...

  • Page 16: Controls

    6 CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automati- cally. S03355-10 Hand brake lever The hand break lever is fitted on the right side of the handle- bar.

  • Page 17: Light Switch

    CONTROLS 6 Light switch The light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is turned downward. In this position, the low beam and tail light are switched High beam on – Light switch is turned upward. In this position, the high beam and tail light are switched on.

  • Page 18: Abs Button

    Each time the ignition is switched on, all three switch LEDs light up for a function check. If all three LEDs light up during operation, a malfunction has been detected by the engine control unit. Contact an authorized KTM workshop immediately. H02887-01...

  • Page 19: Ignition And Steering Lock

    35) is not active. If the TC indicator lamp and both riding mode lamps light up at same time, a malfunction has been detected. Contact an authorized KTM workshop. The TC indicator lamp flashes if the cornering MTC actively engages.

  • Page 20: Seat Release

    6 CONTROLS 6.13 Seat release The loop unlocks the seat. Info The loop for unlocking the seat is located under the fuel tank cap. S04383-10 6.14 Grab handles The grab handles are used for moving the motorcycle around. If you carry a passenger, the passenger can hold onto the grab handles during the trip.

  • Page 21: Foot Brake Lever

    CONTROLS 6 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.17 Foot brake lever Foot brake lever is located in front of the right footrest. The rear brake is engaged with the foot brake lever. 401956-10 6.18 Side stand...

  • Page 22: Closing The Fuel Tank Filler Cap

    6 CONTROLS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. –...

  • Page 23: Activation And Test

    CONTROLS 6 6.21.2 Activation and test Activating combination instrument The combination instrument is activated when the ignition is switched on. Display test To enable you to check that the display is functioning properly, all display segments light up briefly. S04360-01 6.21.3 Setting the combination instrument Condition...

  • Page 24: Setting The Clock

    6 CONTROLS – Press and hold both buttons for 3 – 5 seconds. The Setup menu is displayed. – Press the + button repeatedly until kmor mp flashes on the indicator. – Press the ‑ button to change from km to mp or from mp to km. –...

  • Page 25: Distance 1

    CONTROLS 6 6.21.7 Distance 1 – Press the + or ‑ button repeatedly until TR1 is shown on the combination instrument. TR1 shows the distance 1 since the last reset, such as between two refueling stops. Info If the value of 9999.9 is exceeded, TR1 is automatically reset to 0.0.

  • Page 26: Average Speed 2

    6 CONTROLS 6.21.10 Average speed 2 – Press the + or ‑ button repeatedly until A2 is shown on the combination instrument. A2 shows average speed 2 since the last reset. Briefly press Next display mode the button Briefly press Next display mode the button A2 is reset to 0.0.

  • Page 27: 6.21.14 Clock

    CONTROLS 6 6.21.14 Clock – Press the + or ‑ button repeatedly until CLK is shown on the combination instrument. CLK shows the time. S04377-01 6.21.15 Service interval display – Press the + or ‑ button repeatedly until SER is shown on the combination instrument.

  • Page 28: 6.21.17 Odometer

    The service display is at the top left of the display. Info If the service display appears, a service is due. Contact an authorized KTM workshop. S04382-01 6.21.20 Distance fuel reserve When the fuel level has reached the reserve mark, TR1 F appears on the display, and the fuel level warning lamp lights up.

  • Page 29: Preparing For Use 7

    When using your vehicle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-sales inspection work has been carried out by an authorized KTM workshop. You will receive a delivery certificate when the vehicle is handed over.

  • Page 30: Running In The Engine

    7 PREPARING FOR USE – Run the engine in. ( p. 28) Running in the engine – During the run-in phase, do not exceed the specified vehicle speed in the respective gear. Guideline During the first 1,000 km (620 mi) Maximum speed per gear First gear 45 km/h (28 mph)
  • Page 31 PREPARING FOR USE 7 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 32: Riding Instructions

    8 RIDING INSTRUCTIONS 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 33 Take the weight off the side stand and swing it back up with your foot as far as it will go. Switching off the ABS KTM recommends riding with ABS at all times. However, situa- tions may arise in which ABS is not advantageous. Condition The motorcycle is stationary.

  • Page 34: Starting Off

    8 RIDING INSTRUCTIONS Starting off – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully. Shifting, riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control. –...
  • Page 35 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 36 – If the oil pressure warning lamp lights up, stop immediately, taking care not to endanger yourself or other road users in the process, and switch off the engine. Contact an authorized KTM workshop. – If the malfunction indicator lamp...

  • Page 37: Quickshifter

    RIDING INSTRUCTIONS 8 Quickshifter + If the quickshifter + is activated, you can shift up and down with- out actuating the clutch. Because there is no need to close the throttle grip, uninterrupted gear shifts are possible. The quickshifter + uses the shifter shaft position to check whether or not a shift should be initiated, and sends a corresponding signal to the engine control.

  • Page 38: Braking

    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.) Warning Danger of accidents The brake system fails in the event of overheating.

  • Page 39: Stopping, Parking

    RIDING INSTRUCTIONS 8 – Use the braking effect of the engine on long downhill stretches. Change down one or two gears, but do not over-rev the engine. You will have to apply the brakes far less frequently as a result and the brake system will not overheat.

  • Page 40: Transport

    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.)
  • Page 41 RIDING INSTRUCTIONS 8 Note 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. – Switch off the engine. – Open the fuel tank filler cap. ( p.

  • Page 42: Service Schedule

    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 43: Recommended Work

    Final check: Check the vehicle is roadworthy and take a test ride. ○ ● ● ● ● Read out the fault memory using the KTM diagnostics tool after a test ride. ○ ● ● ● ● Set the service interval. ( p.

  • Page 44: 10 Tuning The Chassis

    10 TUNING THE CHASSIS 10.1 Fork/shock absorber The fork and the shock absorber offer many options for adapting the chassis to the riding style and the payload. Info The recommendations for the suspension setting are shown in table . The table is located on the underside of the front rider's seat.

  • Page 45: Adjusting The Rebound Damping Of The Fork

    Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.)

  • Page 46: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the high-speed compression adjuster can be seen in fast compression of the shock absorber.

  • Page 47: Adjusting The Rebound Damping Of The Shock Absorber

    Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click.

  • Page 48: Adjusting The Handlebar Position

    10 TUNING THE CHASSIS 10.9 Adjusting the handlebar position Warning Danger of accidents A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result. – Change the handlebar if the handlebar is damaged or bent. –...

  • Page 49: Service Work On The Chassis 11

    SERVICE WORK ON THE CHASSIS 11 11.1 Raising the motorcycle with 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. – Insert the adapter in the rear of the lifting gear and screw into the link fork on both sides.

  • Page 50: Removing The Motorcycle From The Lift Stand

    11 SERVICE WORK ON THE CHASSIS 11.4 Removing the motorcycle from the lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Remove the motorcycle from the lift stand and rest it on side stand –...

  • Page 51: Removing Fork Protector

    SERVICE WORK ON THE CHASSIS 11 11.6 Removing fork protector – Remove screws and take off the clamp. – Remove screws on the left fork leg. Take off the fork pro- tector. – Remove screws on the right fork leg. Take off the fork pro- tector.

  • Page 52: Removing The Seat

    11 SERVICE WORK ON THE CHASSIS 11.9 Removing the seat Preparatory work – Open the fuel tank filler cap. ( p. 19) Main work – Pull on loop and raise the rear of the seat. – Pull the seat back and lift it off. S04383-10 Finishing work –...

  • Page 53: Storing The Tool Set

    SERVICE WORK ON THE CHASSIS 11 Main work – Remove the left side cover from the rubber bushing in area – Remove the left side cover upwards from the bushing in area – Take off the left side cover from the front. –...

  • Page 54: Take Off The Side Cover

    11 SERVICE WORK ON THE CHASSIS 11.13 Take off the side cover Preparatory work – Open the fuel tank filler cap. ( p. 19) – Remove the seat. ( p. 50) Main work – Remove the left side cover from the rubber bushing in area –...

  • Page 55: Installing The Front Fender

    SERVICE WORK ON THE CHASSIS 11 Main work – Remove screws – Remove screws and take off the fender. S03291-10 11.16 Installing the front fender Main work – Position the front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis –...

  • Page 56: Installing The Air Filter

    11 SERVICE WORK ON THE CHASSIS 11.18 Installing the air filter Main work – Clean the air filter box. – Mount air filter Info The air filter must lie flush against the air filter box along the entire sealing surface If the air filter is not mounted correctly, dust and dirt may enter the engine and result in damage.

  • Page 57: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 Note 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 58: Adjusting The Chain Tension

    11 SERVICE WORK ON THE CHASSIS – Raise the motorcycle with the rear lifting gear. ( p. 47) Info The check is also possible when the motorcycle is rest- ing on the side stand. – Shift the transmission to neutral position. –...

  • Page 59: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 11 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 60 11 SERVICE WORK ON THE CHASSIS – Pull on the top section of the chain 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 61 SERVICE WORK ON THE CHASSIS 11 – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated.

  • Page 62: Adjusting Chain Guide

    11 SERVICE WORK ON THE CHASSIS 11.24 Adjusting chain guide – Remove screws . Take off the chain guide. Condition Number of teeth: ≤ 44 teeth – Insert nut in hole . Position the chain guide. – Mount and tighten screws Guideline Screw, chain guide 8 Nm (5.9 lbf ft)

  • Page 63: Removing Engine Guard

    SERVICE WORK ON THE CHASSIS 11 Note 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 64: Installing The Engine Guard

    11 SERVICE WORK ON THE CHASSIS 11.28 Installing the engine guard – Slide the engine guard into holders at the rear. – Position the engine guard. Mount and tighten screws both sides. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis S03365-11...

  • Page 65: Brake System 12

    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 pressure. –...

  • Page 66: Adjusting The Basic Position Of The Hand Brake Lever

    12 BRAKE SYSTEM The ABS operates with two independent brake circuits (front and rear brakes). When the ABS control unit detects a locking ten- dency in a wheel, ABS begins regulating the brake pressure. The control function causes a slight pulsing of the hand and foot brake levers.

  • Page 67: 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 68: Adding The Front Brake Fluid

    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.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 69: 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 70 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.

  • Page 71: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 12 – Remove cotter pin , remove pin toward the right by striking it, and remove the brake linings. – Clean the brake caliper and the brake caliper bracket. 400418-11 – Check that spring plate in the brake caliper and sliding plate in the brake caliper bracket are seated correctly.

  • Page 72: Adjusting The Basic Position Of The Foot Brake Lever

    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 73: Adding Rear Brake Fluid

    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.) – Stand the vehicle upright.

  • Page 74: 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 75 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
  • Page 76 12 BRAKE SYSTEM – Remove cotter pin , remove pin toward the left by strik- ing it, and remove the brake linings. – Clean the brake caliper and the brake caliper bracket. B01962-10 – Check that spring plate in the brake caliper and sliding plate in the brake caliper bracket are seated correctly.

  • Page 77: Wheels, Tires 13

    WHEELS, TIRES 13 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) Main work – Manually press the brake caliper toward the brake disc to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons.

  • Page 78: Installing The Front Wheel

    13 WHEELS, TIRES 13.2 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 79 WHEELS, TIRES 13 Main work – Take the brake line out of the guide. R05230-10 – Manually press the brake caliper toward the brake disc to push back the brake piston. – Remove screw and pull wheel speed sensor out of the hole.

  • Page 80: Installing The Rear Wheel

    13 WHEELS, TIRES 13.4 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 81: Checking The Rear Hub Damping Rubber Pieces

    WHEELS, TIRES 13 Guideline Nut, rear wheel spin- M25x1.5 90 Nm (66.4 lbf ft) – Position wheel speed sensor in the hole. – Mount and tighten screw Guideline Screw, wheel speed 6 Nm (4.4 lbf ft) sensor – Position the brake line in the guide. –...

  • Page 82: 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 83: Checking 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 84: Checking The Spoke Tension

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.) –...

  • Page 85: Electrical System 14

    ELECTRICAL SYSTEM 14 14.1 Removing the 12-V battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep 12 V batteries out of the reach of children. – Wear suitable protective clothing and safety glasses. – Avoid contact with battery acid and battery gases.

  • Page 86: Charging The 12-V Battery

    14 ELECTRICAL SYSTEM – Position positive cable with washer – Position negative cable with washer – Mount and tighten the screw. Guideline Screw, battery termi- 4.5 Nm (3.32 lbf ft) S04392-10 – Position positive terminal cover – Position retaining bracket and mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft)
  • Page 87 ELECTRICAL SYSTEM 14 Info Even when there is no load on the 12-V battery, it discharges steadily each day. The charging level and the method of charging are very important for the service life of the 12-V battery. Rapid recharging with a high charging current shortens the service life of the battery. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves.

  • Page 88: Changing The Main Fuse

    14 ELECTRICAL SYSTEM 14.4 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 electrical power consumers of the vehicle. It is in the housing of the starter relay next to the 12-V battery.

  • Page 89: Changing The Abs Fuses

    ELECTRICAL SYSTEM 14 14.5 Changing the ABS fuses Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. Info Two fuses for the ABS are located under the seat. These fuses protect the return pump and the hydraulic unit of the ABS.
  • Page 90 14 ELECTRICAL SYSTEM – Pull off engine electronics control unit from the holder and hang it to the side. Main work – Open fuse box cover S04584-10 – Remove the faulty fuse. Guideline Fuse 1 - 10 A - ignition, combination instrument, clock, engine electronics control unit Fuse 2 - 10 A - ignition, combination instrument, engine electronics control unit...

  • Page 91: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 14 Finishing work – Mount the seat. ( p. 50) 14.7 Removing the headlight mask with the headlight – Cover the fender with a cloth. – Remove screws on both sides. – Tip the headlight mask forward. S03303-10 –...

  • Page 92: Changing The Headlight Bulb

    14 ELECTRICAL SYSTEM – Position the headlight mask. Info Pay attention to routing of the brake line. – Mount and tighten screws Guideline Screw, headlight 5 Nm (3.7 lbf ft) mask S03303-12 Finishing work – Check the headlight setting. ( p.

  • Page 93: Changing The Position Light Lamp

    ELECTRICAL SYSTEM 14 14.10 Changing the position light lamp Note Damage to reflector Grease on the reflector reduces the light intensity. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. – Clean and degrease the bulbs before mounting. –...

  • Page 94: Adjusting The Headlight Range

    14 ELECTRICAL SYSTEM The light-dark boundary must be exactly on the lower mark- ing when the motorcycle is ready to be operated with the rider mounted along with any luggage and a passenger if applicable. » If the boundary between light and dark does not meet specifications: –...

  • Page 95: Diagnostics Connector

    ELECTRICAL SYSTEM 14 14.15 Diagnostics connector Diagnostics connector is located under the engine electronics control unit. S02172-10...

  • Page 96: 15 Cooling System

    15 COOLING SYSTEM 15.1 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 97: Checking The Coolant Level

    COOLING SYSTEM 15 – Place the motorcycle on a horizontal surface using the side stand. – Remove the cover of 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 98: Draining The Coolant

    15 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. – Consult a doctor immediately if coolant is swallowed. –...
  • Page 99 COOLING SYSTEM 15 Condition The engine is cold. Preparatory work – Remove engine guard. ( p. 61) Main work – Position the motorcycle upright. – Position an appropriate container under the engine. – Remove screw . Take off the radiator cap. –...

  • Page 100: Changing The Coolant

    15 COOLING SYSTEM Finishing work – Install the engine guard. ( p. 62) 15.6 Changing the coolant 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 101 COOLING SYSTEM 15 – Mount and tighten screw with a new seal ring. Guideline Screw plug, water M10x1 15 Nm (11.1 lbf ft) pump drain hole 600616-10 – Stand the motorcycle on a level surface using the side stand. – Refill with coolant.

  • Page 102: 16 Tuning The Engine

    16 TUNING THE ENGINE 16.1 Changing the riding mode Info The desired riding mode can be activated via the MAP button on the combination switch. The setting most recently selected is activated again when restarting. The riding mode can also be changed during the ride. Condition Throttle grip closed.

  • Page 103: Checking The Basic Position Of The Shift Lever

    Info If the TC indicator lamp and both riding mode lamps light up at same time, a malfunction has been detected in the traction control. Contact an authorized KTM workshop. 16.3 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position.

  • Page 104: 17 Service Work On The Engine

    17 SERVICE WORK ON THE ENGINE 17.1 Checking the engine oil level Info The engine oil level must be checked when the engine is warm. Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work –...
  • Page 105 SERVICE WORK ON THE ENGINE 17 – Thoroughly clean the oil drain plug with magnet. – Mount the oil drain plug with the magnet and seal ring and tighten it. Guideline Oil drain plug with M12x1.5 20 Nm (14.8 lbf ft) magnet S02209-01 –...
  • Page 106 17 SERVICE WORK ON THE ENGINE – Position oil screen with the O-rings. – Mount and tighten screw plug with the O-ring. Guideline Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) S03324-10 – Position oil screen with the O-rings. –...

  • Page 107: Adding Engine Oil

    123) Info In order to achieve optimal engine oil performance, it is H01066-10 not advisable to mix different engine oils. KTM recommends changing the engine oil where neces- sary. – Mount and tighten filler plug with the O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhal-...

  • Page 108: 18 Cleaning, Care

    18 CLEANING, CARE 18.1 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 109: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE 18 – Push back the protection caps of the handlebar controls to allow any water that has penetrated to evaporate. – After the motorcycle has cooled down, lubricate all moving parts and pivot points. – Clean the chain. ( p.
  • Page 110 18 CLEANING, CARE – Clean the chain. ( p. 54)

  • Page 111: Storage 19

    – 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 a lift stand. ( p. 47) – Cover the motorcycle with a tarp or cover that is permeable to...

  • Page 112: Preparing For Use After Storage

    19 STORAGE 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 the exhaust system to rust.

  • Page 113: Troubleshooting 20

    Join quick release coupling. joined – Malfunction in the electronic Read out the fault memory using the fuel injection KTM diagnostics tool. – Throttle opened while starting When starting, DO NOT open the throt- tle. – Carry out start procedure. ( p.
  • Page 114 – Malfunction in ABS Read out the 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 115: Technical Data 21

    TECHNICAL DATA 21 21.1 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 Idle speed Coolant temperature: ≥ 70 °C (≥ 158 °F) 1,600 ± 50 rpm Control OHC, intake with cam levers, exhaust controlled by rocker arm, chain drive...

  • Page 116: Engine Tightening Torques

    21 TECHNICAL DATA 21.2 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 conrod bearing lubri- 0.8 Nm (0.59 lbf ft) cation Locking screw for bearing 6 Nm (4.4 lbf ft) Loctite ®...
  • Page 117 TECHNICAL DATA 21 Screw, stator 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, tensioning rail M6x30 10 Nm (7.4 lbf ft) Loctite ® 2701™ Screw, thermostat case 10 Nm (7.4 lbf ft) Screw, valve cover 10 Nm (7.4 lbf ft) Screw, water pump cover 10 Nm (7.4 lbf ft) Screw, water pump wheel...

  • Page 118: Capacities

    21 TECHNICAL DATA Engine case stud M16x1.5 25 Nm (18.4 lbf ft) Loctite ® 243™ Rotor nut M18x1.5 100 Nm (73.8 lbf ft) Nut, engine sprocket M20x1.5 100 Nm (73.8 lbf ft) Loctite ® 243™ Nut, inner clutch hub M20x1.5 120 Nm (88.5 lbf ft) Loctite ®...

  • Page 119: Electrical System

    TECHNICAL DATA 21 front Disc brake with dual-piston brake caliper, floating rear Disc brake with single-piston brake caliper, floating Brake discs - diameter front 300 mm (11.81 in) rear 240 mm (9.45 in) Brake discs - wear limit front 4.5 mm (0.177 in) rear 4.5 mm (0.177 in) Tire pressure, road, solo...

  • Page 120: Tires

    140/80 - 18 M/C 70T M+S TT Mitas E‑07 Mitas E‑07 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 21.7 Fork Fork article number 14.18.8S.10 WP SuspensionXPLOR 5348...

  • Page 121: Chassis Tightening Torques

    TECHNICAL DATA 21 Comfort 25 clicks Standard 20 clicks Sport 10 clicks Full payload 10 clicks Spring preload Comfort 18 mm (0.71 in) Standard 18 mm (0.71 in) Sport 18 mm (0.71 in) Full payload 25 mm (0.98 in) Spring rate Soft 66 N/mm (377 lb/in) Medium (standard)
  • Page 122 21 TECHNICAL DATA Screw, throttle grip 3.5 Nm (2.58 lbf ft) Screw, trim M5x12 3.5 Nm (2.58 lbf ft) Spoke nipple, rear wheel 4 Nm (3 lbf ft) Remaining nuts, chassis 10 Nm (7.4 lbf ft) Remaining screws on fuel tank 5 Nm (3.7 lbf ft) Remaining screws, chassis 10 Nm (7.4 lbf ft)
  • Page 123 TECHNICAL DATA 21 Screw, upper part of the air filter 2 Nm (1.5 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)
  • Page 124 21 TECHNICAL DATA Screw, side stand 35 Nm (25.8 lbf ft) Loctite ® 243™ Screw, top shock absorber 45 Nm (33.2 lbf ft) Loctite ® 243™ Banjo bolt, brake line M10x1 25 Nm (18.4 lbf ft) Lambda sensor M12x1.25 25 Nm (18.4 lbf ft) Copper paste Screw, swingarm pivot M12x1.5...

  • Page 125: Substances 22

    SUBSTANCES 22 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 126 22 SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 126) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –...

  • Page 127: Auxiliary Substances 23

    AUXILIARY SUBSTANCES 23 Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer Long-life grease Recommended supplier MOTOREX ® – Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX ® – Moto Clean Off-road chain spray Recommended supplier MOTOREX...

  • Page 128: 24 Standards

    24 STANDARDS JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 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 129: Index Of Special Terms 25

    INDEX OF SPECIAL TERMS 25 Anti-lock braking system Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces Motorcycle Traction Control Auxiliary function of the motor control that reduces engine torque with spinning rear wheel On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics...

  • Page 130: 26 List Of Abbreviations

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

  • Page 131: Green And Blue Symbols

    ABS warning lamp lights up/flashes yellow – If the ABS warning lamp lights up, the ABS is not active. The ABS warning lamp also lights up if a malfunction is detected. Contact an authorized KTM workshop. If the ABS warning lamp flashes slowly, ABS mode Offroad is active.

  • Page 132: Index

    INDEX checking ......57 INDEX Chain tension 12-V battery adjusting ......56 charging .
  • Page 133 INDEX Fork ....... . 42 compression damping, adjusting ..42 Main fuse dust boots, cleaning .
  • Page 134 INDEX Tool set removing ......50 Safe operation ......7 storing .
  • Page 135 *3214279en* 3214279en 02/2021 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

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