KTM 690 Enduro R 2018 Owner's Manual
  1. Manuals
  2. Brands
  3. KTM Manuals
  4. Motorcycle
  5. 690 Enduro R 2018
  6. Owner's manual

KTM 690 Enduro R 2018 Owner's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

OWNER'S MANUAL
2018
690 Enduro R
Art. no. 3213745en

Advertisement

Table of Contents
loading

Related Manuals for KTM 690 Enduro R 2018

Summary of Contents for KTM 690 Enduro R 2018

  • Page 1 OWNER'S MANUAL 2018 690 Enduro R Art. no. 3213745en...
  • 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 VIEW OF VEHICLE ........20 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 9 View of vehicle, front left (example) ... 20 Symbols used ........9 View of vehicle, rear right Formats used........10 (example)........22 SAFETY ADVICE.......... 11 SERIAL NUMBERS ........
  • Page 6 TABLE OF CONTENTS 6.10 Combination instrument ....32 PREPARING FOR USE......... 50 6.10.1 Combination instrument Advice on preparing for first use ..50 overview........32 Running in the engine ...... 52 6.10.2 Function buttons ......33 Loading the vehicle ......53 6.10.3 Tachometer .........
  • Page 7 TABLE OF CONTENTS 10.3 Adjusting the rebound damping of 11 SERVICE WORK ON THE CHASSIS....95 the fork........... 80 11.1 Raising the motorcycle with a lift 10.4 Compression damping of the shock stand ..........95 absorber.......... 81 11.2 Removing the motorcycle from the 10.5 Adjusting the low-speed lift stand .........
  • Page 8 TABLE OF CONTENTS 11.18 Adjusting the basic position of the 12.13 Changing the rear brake linings ..143 clutch lever ........117 13 WHEELS, TIRES ........148 11.19 Checking/correcting the fluid level 13.1 Removing the front wheel .... 148 of the hydraulic clutch....118 11.20 Removing the engine guard.....
  • Page 9 TABLE OF CONTENTS 14.10 Changing the parking light bulb..183 17.2 Changing the engine oil and filter, cleaning the oil screens ....208 14.11 Changing the turn signal bulb ..184 14.12 Checking the headlight setting ..186 17.3 Draining the engine oil ....
  • Page 10 TABLE OF CONTENTS 22.3.2 Coolant ........244 22.3.3 Fuel ......... 244 22.4 Chassis ......... 244 22.5 Electrical system......246 22.6 Tires ..........247 22.7 Fork..........248 22.8 Shock absorber ......249 22.9 Chassis tightening torques ....250 23 SUBSTANCES .......... 257 24 AUXILIARY SUBSTANCES ......

  • Page 11: 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 12: Formats Used

    1 MEANS OF REPRESENTATION 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 13: Safety Advice 2

    SAFETY ADVICE 2 Use definition – intended use The vehicle is designed and constructed to withstand the usual demands of regular traffic and use on gentle ter- rain (unpaved roads). This vehicle is not suitable for use on race tracks. Info This vehicle is only authorized for operation on public roads in its homologated version.

  • Page 14: Degrees Of Risk And Symbols

    2 SAFETY ADVICE 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 15: Tampering Warning

    SAFETY ADVICE 2 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 16: 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 17: Work Rules

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

  • Page 18: 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 19: Important Notes 3

    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 20: 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 21 IMPORTANT NOTES 3 A list of authorized KTM dealers can be found on the KTM website. International KTM Website: http://www.ktm.com...

  • Page 22: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) S02176-10...
  • Page 23 VIEW OF VEHICLE 4 Hand brake lever ( p. 27) Clutch lever ( p. 27) Handrails ( p. 46) Filler cap Passenger footrest ( p. 46) Seat unlocking ( p. 45) Side stand ( p. 48) Shift lever ( p. 47) Engine number ( p.

  • Page 24: View Of Vehicle, Rear Right (Example)

    4 VIEW OF VEHICLE View of vehicle, rear right (example) S02177-10...
  • Page 25 VIEW OF VEHICLE 4 Ignition/steering lock ( p. 31) Light switch ( p. 29) Turn signal switch ( p. 29) Horn button ( p. 28) Function buttons ( p. 33) Indicator lamps ( p. 34) Emergency OFF switch ( p. 30) Electric starter button ( p.

  • Page 26: Serial Numbers

    5 SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. 401945-10 Type label The type label is located on the right side of the frame. H01049-10...

  • Page 27: Key Number

    SERIAL NUMBERS 5 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. 402241-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.

  • Page 28: Fork Part Number

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

  • Page 29: Controls 6

    CONTROLS 6 Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. B01943-10 Hand brake lever The hand break lever is fitted on the right side of the handle- bar.

  • Page 30: Throttle Grip

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

  • Page 31: 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 32: Emergency Off Switch

    6 CONTROLS To switch off the turn signal light, press the turn signal switch towards the switch case. 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 33: Electric Starter Button

    CONTROLS 6 Electric starter button The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position pressed – In this position, the elec- • Electric starter button tric starter is actuated. B01947-11 Ignition/steering lock The ignition/steering lock...

  • Page 34: Combination Instrument

    6 CONTROLS Steering locked – In this position, the ignition circuit is interrupted and the steering locked. The ignition key can be removed. 6.10 Combination instrument 6.10.1 Combination instrument overview The combination instrument is attached in front of the handlebar. The combination instrument is divided into 4 function areas.

  • Page 35: Function Buttons

    CONTROLS 6 6.10.2 Function buttons You can change the display mode with the MODE button Possible display modes are distance traveled (ODO), trip master 1 (TRIP 1) and trip master 2 (TRIP 2). Press the SET button to reset the trip master 1 function ( TRIP 1) and trip master 2 function (TRIP 2) to 0.0.

  • Page 36: Indicator Lamps

    6 CONTROLS 6.10.4 Indicator lamps The indicator lamps offer additional information about the operat- ing state of the motorcycle. Possible states Turn signal indicator lamp flashes green – The turn signal is switched on. The idle indicator lamp lights up green – The trans- mission is in idle.

  • Page 37: Display

    – The OBD has detected an error in the vehicle elec- tronics. Come safely to a halt, and contact an autho- rized KTM workshop. The battery warning lamp lights up red – The voltage in the vehicle system is too low.

  • Page 38: Speed Display

    6 CONTROLS LEnGth After the display function check, the wheel circumference LEnGth is displayed for one second. Info 2205 mm equals the circumference of the 21" front wheel with a series production tire. The display then changes to the last selected mode. 400837-01 6.10.6 Speed display...

  • Page 39: Setting The Kilometers Or Miles

    CONTROLS 6 6.10.7 Setting the kilometers or miles Info If the unit is changed, the value is retained and converted accordingly. Make the setting according to the country. Condition The motorcycle is stationary. – Switch on the ignition by turning the ignition key to position ON –...

  • Page 40: Time

    6 CONTROLS 6.10.8 Time The time is shown in area of the display. Info The time must be reset after the battery was disconnected or the fuse was removed. 400838-11 6.10.9 Setting the clock Condition The motorcycle is stationary. – Switch on the ignition by turning the ignition key to position ON –...

  • Page 41: 6.10.10 Odo Display

    CONTROLS 6 – Keep the MODE button and the SET button pressed simultane- ously. The time is set. 6.10.10 ODO display In the ODO display mode, the total distance traveled is shown in kilometers or miles. Info This value is retained, even if the battery is disconnected from the vehicle and/or the fuse blows.

  • Page 42: Setting/Resetting Display Trip 2

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

  • Page 43: 6.10.13 Trip F Display

    CONTROLS 6 – Switch on the ignition by turning the ignition key to position ON – Press the MODE button repeatedly until the TRIP 2 mode is active. – Keep the SET button pressed. The TRIP 2 display is set to 0.0. 401446-01 6.10.13 TRIP F display If the fuel level drops to the reserve mark, the display automati-...

  • Page 44: 6.10.14 Gear Display

    6 CONTROLS 6.10.14 GEAr display In display mode GEAr, the gear currently engaged is displayed. 401418-01 6.10.15 Coolant temperature indicator The temperature indicator consists of 12 bars. The more bars that light up, the hotter the coolant. When the upper bar lights up, all bars in the display begin to flash and the temperature warning lamp lights up.

  • Page 45: Opening The Filler Cap

    CONTROLS 6 6.11 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 46 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 filler cap and insert the ignition key. –...

  • Page 47: Closing Filler Cap

    CONTROLS 6 6.12 Closing filler cap – Put the filler cap back on and turn the ignition key 90° clock- wise. – Remove the ignition key and fold down the cover. 601771-01 6.13 Seat unlocking The loop unlocks the seat. B01948-10...

  • Page 48: Handrails

    6 CONTROLS 6.14 Handrails The handrails are used for moving the motorcycle around. When you have a passenger, the passenger can hold on the handrails during the journey. 601773-10 6.15 Passenger footrest The passenger footrests are foldable. Possible states Passenger footrest folded in – For operation without a passen- •...

  • Page 49: Shift Lever

    CONTROLS 6 6.16 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 50: Foot Brake Lever

    6 CONTROLS 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 The side stand is located on the left side of the vehicle. The side stand is used for parking the motorcycle.
  • Page 51 CONTROLS 6 Side stand folded in – This position is mandatory when riding • the motorcycle. The safety starting system is inactive.

  • Page 52: 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 53 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 54: Running In The Engine

    7 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 and in a standing position to get a better feeling for the motorcycle. –...

  • Page 55: Loading The Vehicle

    PREPARING FOR USE 7 Loading the vehicle 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. –...
  • Page 56 7 PREPARING FOR USE Warning Danger of accidents Luggage which has slipped impairs visibility. If the tail light is covered, you are less visible to traffic behind you, especially when it is dark. – Check that your luggage is fixed properly at regular intervals. Warning Danger of accidents A high payload alters the handling characteristic and increases the stopping distance.
  • Page 57 PREPARING FOR USE 7 Guideline Maximum permissible overall weight 350 kg (772 lb.) Maximum permissible front axle load 150 kg (331 lb.) Maximum permissible rear axle load 200 kg (441 lb.)

  • Page 58: 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 59: Starting The Vehicle

    RIDING INSTRUCTIONS 8 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. Caution Danger of accidents Electronic components and safety devices will be damaged if the battery is discharged or missing.
  • Page 60 8 RIDING INSTRUCTIONS – Turn the emergency OFF switch to the position – Switch on the ignition by turning the ignition key to position ON After you switch on the ignition, you can hear the fuel pump working for about two seconds. The function check of the combination instrument is run at the same time.
  • Page 61 RIDING INSTRUCTIONS 8 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 62: Starting Off

    8 RIDING INSTRUCTIONS Switching off ABS KTM recommends riding with ABS at all times. However, situa- tions may arise in which ABS is not advantageous. Condition Vehicle stationary, engine running. – for 3 – 5 seconds. Press button The ABS warning lamp starts flashing; ABS is deactivated.
  • Page 63 RIDING INSTRUCTIONS 8 Warning Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine races. – Do not change into a low gear at high engine speed. Warning Danger of accidents An incorrect ignition key position causes malfunctions. –...
  • Page 64 8 RIDING INSTRUCTIONS Warning Danger of accidents Cold tires have reduced road grip. – Ride the first miles carefully on every journey at moderate speed until the tires reach operating tem- perature. Warning Danger of accidents New tires have reduced road grip. The contact surface on new tires is not yet roughened.
  • Page 65 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.
  • Page 66 8 RIDING INSTRUCTIONS – Shift into a higher gear when conditions allow (incline, road situation, etc.). – Release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever, and open the throttle. Info You can see the positions of the 6 forward gears in the figure.
  • Page 67 RIDING INSTRUCTIONS 8 – If the engine stalls (e.g. at a crossroads), just pull the clutch lever and press the electric starter button. You do not have to shift into neutral. – Switch off the engine if running at idle or stationary for a long time.

  • Page 68: Applying The Brakes

    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 69 RIDING INSTRUCTIONS 8 Warning Danger of accidents ABS may increase the stopping distance in certain situations. – Adjust application of the brakes to the respective riding situation and riding surface conditions. Warning Danger of accidents Excessively forceful application of the brakes blocks the wheels. The ABS effectiveness is only ensured if it is switched on.

  • Page 70: Stopping, Parking

    8 RIDING INSTRUCTIONS – 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 71 RIDING INSTRUCTIONS 8 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 72: Transport

    8 RIDING INSTRUCTIONS Transport 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 73: Refueling

    RIDING INSTRUCTIONS 8 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 74 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 75 RIDING INSTRUCTIONS 8 – Press the SET button for two seconds. The fuel level warning lamp goes out. TRIP F is set to 0.0 and the display returns to the previous display mode. Info If you do not press the SET button , the reset takes place automatically after approx.

  • Page 76: 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 77 SERVICE SCHEDULE 9 after every sporting use 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) ● Change the front brake fluid. ● Change the rear brake fluid. ● Change the hydraulic clutch fluid.
  • Page 78 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. ● ● ● Check the CO adjustment using the KTM diagnostics tool. ○ ●...

  • Page 79: Recommended Work

    SERVICE SCHEDULE 9 Recommended work after every sporting use 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 80: 10 Tuning The Chassis

    10 TUNING THE CHASSIS 10.1 Fork/shock absorber The fork and the shock absorber offer many options of adapting the chassis to your riding style and the payload. Info To help you adapt the vehicle, we have summarized our findings in Table .
  • Page 81 TUNING THE CHASSIS 10 – Turn the white adjusting screw all the way clockwise. Info Adjusting screw is located at the upper end of the left fork leg. The compression damping is located in the left fork leg COMP (white adjusting screw). The rebound damp- ing is located in the right fork leg REB (red adjusting screw).

  • Page 82: Adjusting The Rebound Damping Of The Fork

    10 TUNING THE CHASSIS 10.3 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork rebound behavior. – Turn the red adjusting screw all the way clockwise. Info Adjusting screw is located at the upper end of the right fork leg.

  • Page 83: Compression 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.)
  • Page 84 10 TUNING THE CHASSIS Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber. – Turn adjusting screw clockwise with a screwdriver up to the last perceptible click. Info Do not loosen fitting –...

  • Page 85: 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 setting can be seen in fast compression of the shock absorber.

  • Page 86: 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.)

  • Page 87: Measuring The Unloaded Rear Wheel Sag

    TUNING THE CHASSIS 10 – Turn adjusting screw clockwise up to the last perceptible click. – Turn counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping Comfort 20 clicks Standard 15 clicks 100247-10 Sport 10 clicks Full payload 10 clicks...
  • Page 88 10 TUNING THE CHASSIS Main work – Measure the distance – as vertical as possible – between the rear axle and a fixed point, for example, a mark on the rear 0 0 A fairing. – Note down the value as dimension 400988-10 Finishing work –...

  • Page 89: Checking The Static Sag Of The Shock Absorber

    TUNING THE CHASSIS 10 10.9 Checking the static sag of the shock absorber – Measure distance of rear wheel unloaded. ( p. 85) – Hold the motorcycle upright with the aid of an assistant. – Measure the distance between the rear axle and the fixed point 0 0 A again.

  • Page 90: Checking The Riding Sag Of The Shock Absorber

    10 TUNING THE CHASSIS 10.10 Checking the riding sag of the shock absorber – Measure distance of rear wheel unloaded. ( p. 85) – With another person holding the motorcycle, the rider, wear- ing full protective clothing, sits on the seat in a normal sitting 0 0 A position (feet on footrests) and bounces up and down a few times.

  • Page 91: Adjusting The Spring Preload 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 Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
  • Page 92 10 TUNING THE CHASSIS Main work – Release retaining ring – Turn adjusting ring until the spring is fully relaxed. Hook wrench (T106S) – Measure the overall spring length without a load. – Tighten the spring by turning adjusting ring to the speci- fied measurement.

  • Page 93: Adjusting The Riding Sag

    TUNING THE CHASSIS 10 10.12 Adjusting the riding sag Preparatory work – Raise the motorcycle with the work stand. – Remove the seat. ( p. 102) – Take off the side cover. – Remove the shock absorber. – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 94: Handlebar Position

    10 TUNING THE CHASSIS – Adjust the rebound damping of the shock absorber. ( p. 84) 10.13 Handlebar position On the upper triple clamp, there are two holes at a distance of to each other. 15 mm (0.59 in) Hole distance The holes on the handlebar support are placed at a distance of from the center.

  • Page 95: Adjusting Handlebar Position

    TUNING THE CHASSIS 10 10.14 Adjusting handlebar position – Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against damage. Do not bend the cables and lines. –...
  • Page 96 10 TUNING THE CHASSIS – Position the handlebar clamps. Mount screws and tighten evenly. Guideline Screw, handlebar 20 Nm (14.8 lbf ft) clamp...

  • Page 97: Service Work On The Chassis 11

    SERVICE WORK ON THE CHASSIS 11 11.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Use the underride guard underneath the engine to raise the vehicle.

  • Page 98: Cleaning The Dust Boots Of The Fork Legs

    11 SERVICE WORK ON THE CHASSIS – Remove the motorcycle from the lift stand and rest it on side stand – Remove the lift stand. 401943-10 11.3 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p.
  • Page 99 SERVICE WORK ON THE CHASSIS 11 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 nec- essary.

  • Page 100: Loosening The Fork Protection

    11 SERVICE WORK ON THE CHASSIS 11.4 Loosening the fork protection – Remove screws and take off clamp. – Remove screws on left fork leg. Push the fork protection downwards. – Remove screws on the right fork leg. Push the fork protec- tor downward.

  • Page 101: Checking The Play Of The Steering Head Bearing

    Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam- ages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.
  • Page 102 11 SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable on the steering head bearing. » If there is detectable play: –...

  • Page 103: Adjusting The Play Of The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS 11 11.7 Adjusting the play of the steering head bearing Preparatory work – Raise the motorcycle with a lift stand. ( p. 95) Main work – Loosen screw . Remove screw – Loosen and retighten screw Guideline Screw, top steering M20x1.5...

  • Page 104: Removing The Seat

    11 SERVICE WORK ON THE CHASSIS 11.8 Removing the seat – Pull on strap and raise the rear of the seat at the same time. – Pull back the seat and lift it off. B01948-10 11.9 Mounting the seat S02191-10 –...

  • Page 105: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 – Push locking pin into lock housing and push the back of the seat down until the locking pin locks in place with an audible click. – Check, finally, that the seat is correctly mounted. 11.10 Removing the air filter Preparatory work...

  • Page 106: Installing The Air Filter

    11 SERVICE WORK ON THE CHASSIS Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter. – Never start to use the vehicle without an air filter. –...

  • Page 107: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS 11 – Mount and tighten screws Guideline Screw, air filter box 2 Nm (1.5 lbf ft) S02192-11 Finishing work – Mount the seat. ( p. 102) 11.12 Checking the chain for dirt – Check the chain for heavy soiling. »...

  • Page 108: Cleaning The Chain

    11 SERVICE WORK ON THE CHASSIS 11.13 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. – Remove the lubricant from the tires using a suitable cleaning agent. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –...

  • Page 109: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 Main work – Rinse off loose dirt with a soft jet of water. – Remove old grease residue with chain cleaner. Chain cleaner ( p. 261) – After drying, apply chain spray. Off-road chain spray ( p.
  • Page 110 11 SERVICE WORK ON THE CHASSIS – Lean the motorcycle on the side stand. – Shift gear to neutral. – Push the chain upward at a distance from the chain slid- ing guard and determine the chain tension Info The upper chain section must be taut.

  • Page 111: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 11.15 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 112 11 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws the left and right. Guideline Chain tension 5 mm (0.2 in) Turn adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks...

  • Page 113: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 11 11.16 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 95) Main work – Shift the transmission to idle. – Check the rear sprocket and engine sprocket for wear. »...
  • Page 114 11 SERVICE WORK ON THE CHASSIS – Pull at the top part of the chain with the specified weight Guideline Weight of chain wear mea- 15 kg (33 lb.) 0 0 A surement – Measure distance of 18 chain rollers in the lower chain section.
  • Page 115 SERVICE WORK ON THE CHASSIS 11 – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with or below the chain sliding guard: – Replace the chain sliding guard. – Check that the chain sliding guard is firmly seated.
  • Page 116 11 SERVICE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated.
  • Page 117 SERVICE WORK ON THE CHASSIS 11 – Check the chain guide for wear. Info Wear can be seen on the front of the chain guide. » If the light part of the chain guide is worn: – Change the chain guide. 400985-01 –...

  • Page 118: Adjusting Chain Guide

    11 SERVICE WORK ON THE CHASSIS 11.17 Adjusting chain guide – Remove screws . Take off the chain guide. Condition Number of teeth: ≤ 44 teeth – Insert nut in hole . Position the chain guide. – Mount and tighten screws Guideline Screw, chain guide 8 Nm (5.9 lbf ft)

  • Page 119: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS 11 11.18 Adjusting the basic position of the clutch lever Info When the adjusting screw is turned clockwise, the clutch lever moves closer to the handlebar. When the adjusting screw is turned counterclockwise, the clutch lever moves away from the handlebar. The range of adjustment is limited.

  • Page 120: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    11 SERVICE WORK ON THE CHASSIS 11.19 Checking/correcting the fluid level of the hydraulic clutch Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. –...
  • Page 121 SERVICE WORK ON THE CHASSIS 11 Info The fluid level rises with increasing wear of the clutch facing discs. Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts.

  • Page 122: Removing The Engine Guard

    11 SERVICE WORK ON THE CHASSIS Info Clean up overflowed or spilled brake fluid immediately with water. 11.20 Removing the engine guard – Remove screws on the left and right. – Pull the engine guard forward out of the holders and remove it. G00755-11...

  • Page 123: Installing The Engine Guard

    SERVICE WORK ON THE CHASSIS 11 11.21 Installing the engine guard – Slide the engine guard into holders at the rear. – Position the engine guard. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis G00755-10...

  • Page 124: 12 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 125 BRAKE SYSTEM 12 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 126: Adjusting The Basic Position Of The Hand Brake Lever

    12 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 127: 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 128: Checking Brake Fluid Level Of 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 129: Topping Up Brake Fluid Of Front Brake

    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 130 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 131 BRAKE SYSTEM 12 Info Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.

  • Page 132: 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 133: Changing The Front Brake Linings

    131) B01959-01 12.7 Changing the front brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.)
  • Page 134 – 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 Danger of accidents Oil or grease on the brake discs reduces the braking effect.
  • Page 135 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 136 12 BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Press the brake caliper by hand onto the brake disc in order to retract the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does.
  • Page 137 BRAKE SYSTEM 12 – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. – Insert the new brake linings, insert the pin, and mount the cot- ter pin. Info Always change the brake linings in pairs. –...

  • Page 138: Checking The Free Travel Of Foot Brake Lever

    12 BRAKE SYSTEM 12.8 Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.

  • Page 139: Adjusting The Basic Position Of The Foot Brake Lever

    BRAKE SYSTEM 12 12.9 Adjusting the basic position of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
  • Page 140 12 BRAKE SYSTEM – Loosen fittings on foot brake cylinder – To adjust the basic position of the foot brake lever individually, loosen nut and turn screw accordingly. Info The range of adjustment is limited. The screw must be screwed into the footrest bracket by at least four turns. –...

  • Page 141: Checking Rear Brake Fluid Level

    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 142: 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.) Warning Skin irritation Brake fluid causes skin irritation. –...
  • Page 143 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 144: Checking The Rear Brake Linings

    Clean up overflowed or spilt brake fluid immediately with water. 12.12 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.)

  • Page 145: Changing The Rear Brake Linings

    143) B01962-01 12.13 Changing the rear brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.)
  • Page 146 – 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 Danger of accidents Oil or grease on the brake discs reduces the braking effect.
  • Page 147 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 148 12 BRAKE SYSTEM – Stand the vehicle upright. – Remove screw cap with membrane – Press the brake caliper by hand onto the brake disc in order to retract the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does.
  • Page 149 BRAKE SYSTEM 12 – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. – Insert the new brake linings, insert the pin, and mount the cot- ter pin. Info Always change the brake linings in pairs. –...

  • Page 150: 13 Wheels, Tires

    13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 95) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.
  • Page 151 WHEELS, TIRES 13 Warning Danger of accidents Damaged brake discs reduce the braking effect. – Always lay the wheel down in such a way that the brake disc is not damaged. – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork.

  • Page 152: 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 153 WHEELS, TIRES 13 – Clean and grease the wheel spindle. Long-life grease ( p. 261) – Jack up the front wheel into the fork, position it, and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw Guideline Screw, front wheel M24x1.5...

  • Page 154: Removing The Rear Wheel

    13 WHEELS, TIRES Guideline Screw, wheel speed 6 Nm (4.4 lbf ft) sensor 13.3 Removing the rear wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 95) Main work – Remove screw and pull wheel speed sensor out of the hole.
  • Page 155 WHEELS, TIRES 13 – Holding the rear wheel, withdraw wheel spindle B01969-10 – Push the rear wheel forward as far as possible and take the chain off the rear sprocket. Warning Danger of accidents Damaged brake discs reduce the braking effect. –...

  • Page 156: 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 157 WHEELS, TIRES 13 – Clean and grease the thread of the wheel spindle and nut Long-life grease ( p. 261) – Clean and grease the wheel spindle. Long-life grease ( p. 261) – Mount the rubber damper and rear sprocket carrier in the rear wheel.

  • Page 158: Checking The Rear Hub Rubber Dampers

    13 WHEELS, TIRES – Position wheel speed sensor in the drill hole. Mount and tighten screw Guideline Screw, wheel speed 6 Nm (4.4 lbf ft) sensor – Operate the foot brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure point.
  • Page 159 WHEELS, TIRES 13 Main work – Check bearing » If the bearing is damaged or worn: – Replace the bearings. – Check rubber dampers of the rear hub for damage and wear. » If the rubber dampers of the rear hub are damaged or worn: S02205-10 –...

  • Page 160: 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 161 WHEELS, TIRES 13 Warning Danger of accidents New tires have reduced road grip. The contact surface on new tires is not yet roughened. – Run in new tires with moderate riding at alternating angles. Running-in phase 200 km (124 mi) Info The type, condition, and air pressure of the tires all have a major impact on the handling of the motorcy- cle.

  • Page 162: Checking The Tire Air 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 163 WHEELS, TIRES 13 – Remove the protection cap. – Check the tire air pressure when the tires are cold. Tire air pressure, offroad, single rider front 1.5 bar (22 psi) rear 1.5 bar (22 psi) Tire air pressure, road, solo front 1.8 bar (26 psi) 400695-01...

  • Page 164: 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.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes.
  • Page 165 WHEELS, TIRES 13 – Briefly strike each spoke with a screwdriver blade. Info The frequency of the tone is a function of the spoke length and spoke diameter. If you hear different tone frequencies from individual spokes of the same length and thickness, this is an indication of different spoke tensions.

  • Page 166: 14 Electrical System

    14 ELECTRICAL SYSTEM 14.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and safety glasses. – Avoid contact with battery acid and battery gases. –...
  • Page 167 ELECTRICAL SYSTEM 14 Main work – Remove battery cover – Pull engine electronics control unit off of the holder and set it to one side. B01974-10 – Disconnect negative cable from the battery. – Take off positive terminal cover S00622-10...
  • Page 168 14 ELECTRICAL SYSTEM – Disconnect ABS connection cable and positive cable from the battery. S00620-10 – Remove screws – Pull retaining bracket of the battery forward and remove it. – Lift the battery up and out. Info Never operate the motorcycle with a discharged battery or without a battery.

  • Page 169: Installing The Battery

    ELECTRICAL SYSTEM 14 14.2 Installing the battery Main work – Insert the battery into the battery compartment with the termi- nals facing rearward. Battery (YTZ10S) ( p. 246) – Position retaining bracket and mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) S00621-11 chassis...
  • Page 170 14 ELECTRICAL SYSTEM – Position positive terminal cover – Position washer and negative cable , and mount and tighten the screw. Guideline Screw, battery termi- 4.5 Nm (3.32 lbf ft) S00622-11 – Position the engine electronics control unit – Mount battery cover S00624-10 Finishing work –...

  • Page 171: Recharging The Battery

    ELECTRICAL SYSTEM 14 14.3 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 172 14 ELECTRICAL SYSTEM Info Even when there is no load on the battery, it still loses power steadily. The charging level and the method of charging are very important for the service life of the battery. Rapid recharging with a high charging current shortens the battery's service life. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves.
  • Page 173 ELECTRICAL SYSTEM 14 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 rest potential and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the battery.

  • Page 174: Changing The Main Fuse

    14 ELECTRICAL SYSTEM – Set the clock. ( p. 38) 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 power consumers of the vehicle.
  • Page 175 ELECTRICAL SYSTEM 14 Main work – Take off protection caps B01977-10 – Remove a defective main fuse with needle nose pliers. Info A defective fuse is indicated by a burned-out fuse wire A spare fuse is located in the starter relay. –...

  • Page 176: Changing The Abs Fuses

    14 ELECTRICAL SYSTEM Finishing work – Mount the seat. ( p. 102) – Set the clock. ( p. 38) 14.5 Changing the ABS fuses Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. –...
  • Page 177 ELECTRICAL SYSTEM 14 To change the fuse of the ABS hydraulic unit: – Take off protection cap and remove the fuse. – Insert a new fuse. Fuse (58011109115) ( p. 246) – Mount the protection cap. B01979-10 To change the fuse of the ABS return pump: –...

  • Page 178: Changing The Fuses Of Individual Power Consumers

    14 ELECTRICAL SYSTEM 14.6 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work – Switch off the ignition by turning the ignition key to position OFF –...
  • Page 179 ELECTRICAL SYSTEM 14 – Remove the faulty fuse. Guideline Fuse 1 - 10 A - ignition Fuse 2 - 10 A - ignition, combination instrument, engine electronics control unit, lambda sensor Fuse 3 - 10 A - fuel pump Fuse 4 - 10 A - radiator fan Fuse 5 - 10 A - horn, brake light, turn signal S02238-10 Fuse 6 - 15 A - high beam, low beam, parking light, tail...
  • Page 180 14 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 181: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM 14 14.7 Removing the headlight mask with the headlight – Switch off the ignition by turning the ignition key to position OFF – Cover the fender with a cloth to protect it from damage. – Remove screws on both sides. –...

  • Page 182: Installing The Headlight Mask With The Headlight

    14 ELECTRICAL SYSTEM 14.8 Installing the headlight mask with the headlight Main work – Connect plug-in connectors of the headlight and of the turn signals. – Check that the lighting is functioning properly. 601794-11 – Remove the cloth from the fender and position the headlight mask.

  • Page 183: Changing The Headlight Bulb

    ELECTRICAL SYSTEM 14 – Position line guides . Mount and tighten screws Guideline Screw, headlight 5 Nm (3.7 lbf ft) mask B01982-11 Finishing work – Check the headlight setting. ( p. 186) 14.9 Changing the headlight bulb Note Damage to reflector Grease on the reflector reduces the brightness. Grease on the bulb will evaporate due to the heat and be deposited on the reflector.
  • Page 184 14 ELECTRICAL SYSTEM Main work – Unplug connector – Take off protection cap of the headlight bulb. 600610-10 – Detach spring bar – Remove headlight bulb – Insert a new headlight bulb into the headlight housing. Headlight (H4 / socket P43t) ( p.

  • Page 185: Changing The Parking Light Bulb

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

  • Page 186: Changing The Turn Signal Bulb

    14 ELECTRICAL SYSTEM – Pull bulb socket out of the reflector. – Pull parking light bulb out of the bulb socket. – Insert a new parking light bulb in the bulb socket. Parking light (W5W / socket W2.1x9.5d) ( p. 247) –...
  • Page 187 ELECTRICAL SYSTEM 14 Main work – Remove the screw on the rear of the turn signal housing. – Tilt headlamp diffuser forward carefully and take it off. – Lightly squeeze orange cap in the area of the holding lugs and take it off. –...

  • Page 188: Checking The Headlight Setting

    14 ELECTRICAL SYSTEM 14.12 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 189: Adjusting The Headlight Range

    ELECTRICAL SYSTEM 14 14.13 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 186) Main work – Turn adjusting screw to adjust the headlight range. Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider (instructions on how to apply the mark: Checking the headlight setting).

  • Page 190: Diagnostics Connector

    14 ELECTRICAL SYSTEM 14.14 Diagnostics connector Diagnostics connector is located under the engine control unit. S02172-10...

  • Page 191: Cooling System 15

    COOLING SYSTEM 15 15.1 Cooling system The water pump in the engine forces the coolant to flow. The pressure in the cooling system resulting from heat is regu- lated by a valve in the radiator cap . The heat expansion causes the surplus coolant to flow into the compensating tank .

  • Page 192: Checking The Antifreeze And Coolant Level

    15 COOLING SYSTEM 15.2 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 193 COOLING SYSTEM 15 – Stand the motorcycle on its side stand on a horizontal surface. – 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 194 15 COOLING SYSTEM – Remove radiator cap – 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: – Correct the antifreeze in the coolant. –...

  • Page 195: Checking The Coolant Level

    COOLING SYSTEM 15 15.3 Checking the 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 196 15 COOLING SYSTEM – Stand the motorcycle on its side stand on a horizontal surface. – Check the coolant level in compensating tank The coolant level must be within the range shown in the fig- ure. » If the coolant level does not match the specified value: –...

  • Page 197: Draining The Coolant

    COOLING SYSTEM 15 15.4 Draining 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 198 15 COOLING SYSTEM Main work – Position the motorcycle upright. – Place a suitable container under the engine. – Remove screw . Remove the radiator cap. – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Plug, drain hole of M10x1...

  • Page 199: Filling/Bleeding The Cooling System

    COOLING SYSTEM 15 15.5 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 200 15 COOLING SYSTEM – Refill with coolant. Coolant ( p. 257) – Completely fill the radiator with coolant. – Mount radiator cap 601800-10 – Remove the cover of compensating tank – Add coolant to the level shown in the figure. –...

  • Page 201: Changing The Coolant

    COOLING SYSTEM 15 – Check the coolant level. ( p. 193) 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 202 15 COOLING SYSTEM Main work – Position the motorcycle upright. – Place a suitable container under the engine. – Remove screw 600616-10 – Remove radiator cap – Completely drain the coolant. 601799-10...
  • Page 203 COOLING SYSTEM 15 – Mount and tighten screw with a new seal ring. Guideline Plug, drain hole of M10x1 15 Nm (11.1 lbf ft) water pump 600616-10 – Stand the motorcycle on its side stand on a horizontal surface. – Refill with coolant.
  • Page 204 15 COOLING SYSTEM – Remove cover of the compensating tank. – Add coolant to the level shown in the figure. – Mount cover of the compensating tank. Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. –...

  • Page 205: Tuning The Engine 16

    TUNING THE ENGINE 16 16.1 Adjusting the engine characteristic Preparatory work – Switch off the ignition by turning the ignition key to position OFF – Remove the seat. ( p. 102) Main work – Pull the Map‑Select switch and holder upward off of the retaining bracket.

  • Page 206: Checking The Basic Position Of The Shift Lever

    16 TUNING THE ENGINE Advanced – homologated performance with extremely direct responsiveness. Set the Map‑Select switch to Standard. – Set the adjusting wheel to position 3, 4, 5, 6, 7, 8 or 9. Standard – homologated performance with balanced responsiveness. Set the Map‑Select switch to poor fuel quality.

  • Page 207: Adjusting The Basic Position Of The Shift Lever

    TUNING THE ENGINE 16 – Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the shift lever. Distance between shift lever 10 … 20 mm (0.39 … and upper edge of boot 0.79 in) 0 0 0 A »...
  • Page 208 16 TUNING THE ENGINE – Clean gear teeth of the shift lever and shift shaft. – Mount shift lever on the shift shaft in the required position and engage the gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure.

  • Page 209: Service Work On The Engine 17

    SERVICE WORK ON THE ENGINE 17 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 210: Changing The Engine Oil And Filter, Cleaning The Oil Screens

    17 SERVICE WORK ON THE ENGINE 17.2 Changing the engine oil and filter, cleaning the oil screens – Drain the engine oil. p. 208) – Remove the oil filter. p. 210) – Clean the oil screens. p. 211) – Install the oil filter. p.
  • Page 211 SERVICE WORK ON THE ENGINE 17 Info Drain the engine oil while the engine is at operating temperature. Preparatory work – Remove the engine guard. ( p. 120) Main work – Place a suitable container under the engine. – Remove oil drain plug with the magnet and seal ring.

  • Page 212: Removing The Oil Filter

    17 SERVICE WORK ON THE ENGINE 17.4 Removing the oil filter Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden. – Wear suitable protective clothing and safety gloves. – In the event of scalding, rinse the area affected immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 213: Cleaning The Oil Screens

    SERVICE WORK ON THE ENGINE 17 – Remove screws . Remove the oil filter cover with the O-ring. – Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) – Completely drain the engine oil. – Thoroughly clean the parts and sealing area. S02212-10 17.5 Cleaning the oil screens...
  • Page 214 17 SERVICE WORK ON THE ENGINE Main work – Remove screw plug with oil screen and the O-rings. S02213-10 – Remove screw plug with oil screen and the O-rings. – Completely drain the engine oil. – Thoroughly clean the parts and sealing surface. S02214-10...
  • Page 215 SERVICE WORK ON THE ENGINE 17 – 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) S02215-10 – Position oil screen with the O-rings. –...

  • Page 216: Installing The Oil Filter

    17 SERVICE WORK ON THE ENGINE 17.6 Installing the oil filter – Insert oil filters – Oil the O-rings of the oil filter covers. Mount oil filter cov- – Mount and tighten the screws. Guideline Screw, oil filter cover 6 Nm (4.4 lbf ft) S02217-10 17.7 Filling up with engine oil...
  • Page 217 SERVICE WORK ON THE ENGINE 17 Main work – Remove filler plug with O-ring from the clutch cover and add engine oil. Engine oil 1.70 l Engine oil (1.8 qt.) (SAE 10W/60) (00062010035) p. 258) Engine oil Engine oil Alternative engine oil (SAE 10W/50) M00649-10 p.

  • Page 218: Adding Engine Oil

    17 SERVICE WORK ON THE ENGINE – Check the engine oil level. ( p. 207) 17.8 Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear of the engine. Main work – Remove filler plug and the O-ring from the clutch cover, and fill up with engine oil.
  • Page 219 SERVICE WORK ON THE ENGINE 17 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. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

  • Page 220: 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 221 CLEANING, CARE 18 – 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 222 18 CLEANING, CARE – After cleaning, ride a short distance until the engine reaches operating temperature. Info The heat produced causes water at inaccessible loca- tions in the engine and brake system to evaporate. – Push back the protection covers of the handlebar controls to allow any water that has penetrated to evaporate.

  • Page 223: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE 18 Special cleaner for glossy and matte paint finishes, metal and plastic surfaces ( p. 262) – Lubricate the ignition/steering lock. Universal oil spray ( p. 262) 18.2 Checks and maintenance steps for winter operation Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precau- tions against aggressive road salt.
  • Page 224 18 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 225: Storage 19

    STORAGE 19 19.1 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 226 19 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 a lift stand. ( p. 95) – Cover the motorcycle with a tarp or similar cover that is perme- able to air.

  • Page 227: Preparing For Use After Storage

    STORAGE 19 19.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 95) – Recharge the battery. p. 169) – Install the battery. p. 167) – Set the clock. ( p. 38) – Perform checks and maintenance measures when preparing for use.

  • Page 228: 20 Troubleshooting

    ( p. 176) – 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 229 Change fuel screen. – Fuel filter is very dirty Check the fuel pressure. – Defect in fuel injection system Read out the fault memory using the KTM diagnostics tool. – Map‑Select switch incorrectly Adjust the engine characteristic. adjusted p. 203) –...
  • Page 230 – 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 231 TROUBLESHOOTING 20 Faults Possible cause Action – High oil consumption Engine oil too thin (low viscos- Change the engine oil and filter, clean ity) the oil screens. p. 208) – Headlight and parking light are Fuse 6 blown Change the fuses of individual power not functioning consumers.

  • Page 232: 21 Blink Code

    21 BLINK CODE Blink code for malfunction indicator lamp 02 Malfunction indicator lamp flashes 2x short Error level condition Crankshaft position sensor - circuit fault Blink code for malfunction indicator lamp 09 Malfunction indicator lamp flashes 9x short Error level condition Manifold absolute pressure sensor cylinder 1 - input signal too low Manifold absolute pressure sensor cylinder 1 - input signal too high Blink code for malfunction...
  • Page 233 BLINK CODE 21 Blink code for malfunction indicator lamp 14 Malfunction indicator lamp flashes 1x long, 4x short Error level condition Ambient air pressure sensor - input signal too low Ambient air pressure sensor - input signal too high Blink code for malfunction indicator lamp 15 Malfunction indicator lamp flashes 1x long, 5x short Error level condition...
  • Page 234 21 BLINK CODE Blink code for malfunction indicator lamp 24 Malfunction indicator lamp flashes 2x long, 4x short Error level condition System voltage - circuit fault Blink code for malfunction indicator lamp 25 Malfunction indicator lamp flashes 2x long, 5x short Error level condition Side stand switch - circuit fault Blink code for malfunction...
  • Page 235 BLINK CODE 21 Blink code for malfunction indicator lamp 39 Malfunction indicator lamp flashes 3x long, 9x short Error level condition Ignition coil 2, cylinder 1 - circuit fault Blink code for malfunction indicator lamp 41 Malfunction indicator lamp flashes 4x long, 1x short Error level condition Fuel pump controller - short circuit to ground or open circuit Fuel pump controller - input signal too high...
  • Page 236 21 BLINK CODE Blink code for malfunction indicator lamp 82 Malfunction indicator lamp flashes 8x long, 2x short Error level condition Throttle position sensor circuit A - input signal too high Throttle position sensor circuit A - input signal too low Blink code for malfunction indicator lamp 83 Malfunction indicator lamp flashes 8x long, 3x short...
  • Page 237 BLINK CODE 21 Blink code for malfunction indicator lamp 86 Malfunction indicator lamp flashes 8x long, 6x short Error level condition Accelerator position sensor circuit B - input signal too high Blink code for malfunction indicator lamp 87 Malfunction indicator lamp flashes 8x long, 7x short Error level condition Accelerator position sensor circuit A and B - plausibility fault Blink code for malfunction...
  • Page 238 21 BLINK CODE Blink code for malfunction indicator lamp 92 Malfunction indicator lamp flashes 9x long, 2x short Error level condition DBW throttle actuator control IC - stuck open Blink code for malfunction indicator lamp 93 Malfunction indicator lamp flashes 9x long, 3x short Error level condition CPU mutual - surveillance error Blink code for malfunction...

  • Page 239: Technical Data 22

    TECHNICAL DATA 22 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 690 cm³ (42.11 cu in) Stroke 84.5 mm (3.327 in) Bore 102 mm (4.02 in) Compression ratio 12.6:1 Idle speed Coolant temperature: ≥ 70 °C (≥ 158 °F) 1,550 … 1,650 rpm Control OHC, 4 valves controlled via rocker arm, chain drive Valve diameter, intake...
  • Page 240 22 TECHNICAL DATA 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 digital ignition adjustment...

  • Page 241: Engine Tightening Torques

    TECHNICAL DATA 22 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 conrod bearing lubri- 2 Nm (1.5 lbf ft) Loctite ® 243™...
  • Page 242 22 TECHNICAL DATA Screw in alternator cover 10 Nm (7.4 lbf ft) Screw, alternator cover (chain 10 Nm (7.4 lbf ft) Loctite ® 243™ shaft through-hole) Screw, autodecompression 3 … 4 Nm (2.2 … 3 lbf ft) Loctite ® 243™ Screw, axial lock of camshaft 10 Nm (7.4 lbf ft) Loctite...
  • Page 243 TECHNICAL DATA 22 Screw, rocker arm shaft 12 Nm (8.9 lbf ft) Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, shift lever 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, starter motor 10 Nm (7.4 lbf ft) Loctite ®...
  • Page 244 22 TECHNICAL DATA Stud, exhaust flange 10 Nm (7.4 lbf ft) Loctite ® 243™ 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)
  • Page 245 TECHNICAL DATA 22 Spark plug inside M12x1.25 18 Nm (13.3 lbf ft) 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...

  • Page 246: 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. 258) Engine oil Engine oil (SAE 10W/50) Alternative engine oil p. 259) 22.3.2 Coolant Coolant 1.20 l (1.27 qt.) Coolant ( p.
  • Page 247 TECHNICAL DATA 22 Shock absorber WP Performance Systems 4618 with Pro‑Lever linkage Suspension travel front 250 mm (9.84 in) rear 250 mm (9.84 in) Brake system front Disc brake with dual-piston brake caliper, floating rear Disc brake with single-pot brake caliper, floating Brake discs - diameter front 300 mm (11.81 in)

  • Page 248: Electrical System

    22 TECHNICAL DATA rear 1.5 bar (22 psi) Secondary drive ratio 15:45 Chain 5/8 x 1/4” X‑ring Steering head angle 63° Wheelbase 1,504 ± 15 mm (59.21 ± 0.59 in) Seat height unloaded 910 mm (35.83 in) Ground clearance unloaded 280 mm (11.02 in) Weight without fuel, approx.

  • Page 249: Tires

    90/90 - 21 M/C 54S TT 140/80 - 18 M/C 70S TT Metzeler Enduro 3 Sahara Metzeler Enduro 3 Sahara The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com...

  • Page 250: Fork

    22 TECHNICAL DATA 22.7 Fork Fork part number 14.18.8N.10 WP Performance Systems 4860 MXTA SPLIT Fork Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks...

  • Page 251: Shock Absorber

    TECHNICAL DATA 22 22.8 Shock absorber Shock absorber article number 15.18.7L.10 WP Performance Systems 4618 with Pro‑Lever linkage Shock absorber Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1 turn Full payload 1 turn Compression damping, low-speed Comfort 20 clicks Standard 15 clicks...

  • Page 252: Chassis Tightening Torques

    22 TECHNICAL DATA Hard 85 N/mm (485 lb/in) Spring length 220 mm (8.66 in) Gas pressure 10 bar (145 psi) Static sag 18 mm (0.71 in) Riding sag 70 … 80 mm (2.76 … 3.15 in) Fitted length 395 mm (15.55 in) Shock absorber fluid ( p.
  • Page 253 TECHNICAL DATA 22 Remaining screws, chassis 4 Nm (3 lbf ft) Screw, brake line holder on 4 Nm (3 lbf ft) swingarm Screw, cable on starter motor 3 Nm (2.2 lbf ft) Screw, combination switch, left 3.5 Nm (2.58 lbf ft) Screw, electrical holder 3 Nm (2.2 lbf ft) Screw, exhaust heat shield...
  • Page 254 22 TECHNICAL DATA Screw, ABS control unit 5 Nm (3.7 lbf ft) Screw, ABS module retaining 10 Nm (7.4 lbf ft) bracket on frame Screw, air filter box top 2 Nm (1.5 lbf ft) Screw, ball joint of push rod on 10 Nm (7.4 lbf ft) Loctite ®...
  • Page 255 TECHNICAL DATA 22 Screw, magnetic holder on side 6 Nm (4.4 lbf ft) Loctite ® 243™ stand Screw, radiator bleeding 8 Nm (5.9 lbf ft) Screw, radiator guard 8 Nm (5.9 lbf ft) Screw, rear brake disc 14 Nm (10.3 lbf ft) Loctite ®...
  • Page 256 22 TECHNICAL DATA Screw, fork stub 15 Nm (11.1 lbf ft) Screw, front brake caliper 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, front footrest bracket 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, fuel tank bracket 15 Nm (11.1 lbf ft) Screw, fuel tank, bottom 25 Nm (18.4 lbf ft) Loctite...
  • Page 257 TECHNICAL DATA 22 Screw, spring holder on side stand 25 Nm (18.4 lbf ft) Loctite ® 243™ bracket Screw, steering stem 20 Nm (14.8 lbf ft) Screw, top triple clamp 17 Nm (12.5 lbf ft) Engine carrying screw 45 Nm (33.2 lbf ft) Loctite ®...
  • Page 258 22 TECHNICAL DATA Screw, radiator temperature sensor 20 Nm (14.8 lbf ft) Screw, bottom steering head M20x1.5 60 Nm (44.3 lbf ft) Loctite ® 243™ Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) Nut, rear wheel spindle M25x1.5...

  • Page 259: Substances 23

    SUBSTANCES 23 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 260 JASO T903 MA ( p. 263) – SAE ( p. 263) (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 261 SUBSTANCES 23 Engine oil (SAE 10W/50) Standard/classification – JASO T903 MA ( p. 263) – SAE ( p. 263) (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 262 23 SUBSTANCES Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification – DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline –...

  • Page 263: Auxiliary Substances 24

    AUXILIARY SUBSTANCES 24 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 264 24 AUXILIARY SUBSTANCES Perfect Finish and high gloss polish for paints Recommended supplier Motorex ® – Moto Polish & Shine Preserving materials for paints, metal and rubber Recommended supplier Motorex ® – Moto Protect Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier Motorex ®...

  • Page 265: Standards 25

    STANDARDS 25 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 266: 26 Index Of Special Terms

    26 INDEX OF SPECIAL TERMS Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics...

  • Page 267: List Of Abbreviations 27

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

  • Page 268: 28 List Of Symbols

    Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized KTM workshop. ABS warning lamp lights up/flashes yellow – Status or error messages relating to ABS.

  • Page 269: Green And Blue Symbols

    LIST OF SYMBOLS 28 28.3 Green and blue symbols Green and blue symbols reflect information. Turn signal indicator lamp flashes green – 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 270: Index

    INDEX Brake fluid level INDEX checking the brake fluid level of front brake . 126 ABS ....... 122 rear brake, checking .
  • Page 271 INDEX checking ......107 Coolant changing ......199 Changing the headlight bulb .
  • Page 272 INDEX Engine oil Fork protector adding ......216 positioning ......98 changing .
  • Page 273 INDEX Implied warranty ......17 Oil screens Intended use ......11 cleaning .
  • Page 274 INDEX removing ......152 rebound damping, adjusting ... . . 84 riding sag, checking .
  • Page 275 INDEX engine tightening torques ... . . 239 fork ......248 Warranty .
  • Page 276 *3213745en* 3213745en 08/2017 KTM Sportmotorcycle GmbH Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com...

Table of Contents