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KTM 690 Enduro R 2018 Repair Manual
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KTM 690 Enduro R 2018 Repair Manual

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REPAIR MANUAL 2018
690 Enduro R
Art.
3206323en
no.

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Summary of Contents for KTM 690 Enduro R 2018

  • Page 1 REPAIR MANUAL 2018 690 Enduro R Art. 3206323en...
  • Page 3 The models contain that does not belong errors. regular supply. scope of Sportmotorcycle Mattighofen © 2017 KTM GmbH, Austria rights reserved Reproduction, part, copying permitted only permission well of all kinds, with the express written...
  • Page 4 Adjusting steering bearing 6.13 MEANS OF REPRESENTATION ..ccseecneeeeee 7 head DIBY iesccvacasncsvauwssavensanvinsevsvivswxnisansnes SVYMBGIS Asi. US6E) cccssniccsesrncaserimauvavcraewan HANDLEBAR; CONTROLS FOrMats USE0 S:escxsenerenes svc cccsiscsssvssneeweimesearssawewee position Handlebar SAFELY ADVIC Excise .....:ccceeeeeeeees mney Adjusting position..... handlebar Repair MANUAL Changing the throttle grip... wsccccsccseeesnevoenmenasevenansns Safety cess GOAVICE...
  • Page 5 Installing Checking linings..11.4 the air filter box....0... 70 15.2 the front brake linings..Changing 15.3. the front brake TANK, SEAT, FUEL TRIM 15.4 Checking the free travel of the ....ccceeeeeeeees Opening hand brake lever 12.1 thefiller Cap.......c.0cceceeeeseees cee ceseeees Adjusting Clostnig-titler: 15.5...
  • Page 6 Removing Checking/measuring piston..17.3.9 the thermostat.... 143 17.4.13 Setting ignition top Checking piston ring engine 17.3.10 17.4.14 ead CONEr cscsesccscesseeceweesssvscas sccave cocmssvecnesarwenmwesarseseneseanes Removing spark plugs... Determining piston/cylinder 17.3.11 17.4.15 mounting clearance..c.cceeeeee 167 Removing timing 17.3.12 chain TENSIONEL..cceceeeceeeeeeeeeeaneeueennes 144 17.4.16 Checking pumps for wear..
  • Page 7 Installing timing Draining engine 17.5.14 chain and 21.5 ....08. sprocket....timing chain Removing 21.6 the oil filter....0. Installing timing 175.15 chain rails... 21.7 ‘Installing the oil filter..... Installing 17.5.16 rotor Cleaning 21.8 the oil screens........0 Adjusting position 17.5.17 crankshaft Filling engine 21.9...
  • Page 8 Page 28:38 O8 0f 21 scenes Page 28:9 OS of 11 susie Page 28.10 1Ovof 11 causes: Page 28.11. ll:of 11] causes: SUBSTANCES ccsscesscevessnnsenevenaveseoanemnmneenne AUXILIARYSUBSTANCES..:cesseeeeeeeeee 280 SPECIAL TOOLS..cceceeeeceeeeeeeeeeeeeeeeeeeees 282 STANDARDS uccesccscsssscsscerssazsassazeeceevessasnsas 301 INDEX OF SPECIAL TERMS....ccccceeereee LIST OF ABBREVIATIONS..:::cseeeseeeeeeees 303 INDEX sssscss asics...
  • Page 9 specific meaning symbols is described below. expected (e.g. Indicates reaction work step function). or a unexpected (e.g. Indicates reaction work step function). or a provided specified page). Indicates page reference (more information is Indicates information with tips. details more testing Indicates the result of step.
  • Page 10 It contains useful information and help repair that will and maintain your vehicle. special workplace workshop equipment This manual that the necessary KTM tools and KTM assumes available. safety safely. A numberof instructions need to be followed operate the model described Therefore read this instruction and all further instructions included carefully.
  • Page 11 KTM. KTM accepts for other spare products resulting damage and any loss. The current KTM PowerParts for your vehicle be found the KTM website. http://www.ktm.com International KTM Website: figures depict special equipment. contained in the manual may clarity,...
  • Page 12 stamped steering The chassis number head right. 401945-10 (690 Enduro R right type label is located side of the frame. Ho1049-10 (690 Enduro R right type label USA is located side of the frame. type label Canada is located the left side of the frame.
  • Page 13 engine stamped engine number the left side of the under the engine sprocket. 401949- be found the KEYCODECARD. number Info key. Keep You need the numberto order spare the KEYCODECARD in safe place. 402241-10 stamped The fork part number the inner side of the fork stub.
  • Page 14 Note Danger damage parked vehicle roll or fall away over. Park the vehicle firm and level surface. on a — guard engine Use the underride underneaththe to raise the — vehicle. ground. ” Neither wheel is in contact with the motorcycle against falling Secure the over.
  • Page 15 motorcycle upright, align special Position the tool, raise the motorcycle. (62529055100) ('" 287) Work stand 300201-10 Note Danger damage parked vehicle roll fall away over. Park the vehicle firm and level surface. on a — Secure the motorcycle against falling over.
  • Page 16 — your foot it will go. Switching off ABS riding However, KTM recommends with ABS at all times. situa- advantageous. tions may arise in which ABSis not Condition stationary, engine running. Vehicle Press button for 3 5 seconds.
  • Page 17 position Turn the emergency OFF switch ©. to the Shift gear to neutral. ignition. Switch Press the electric button ®. starter Info Do not open the throttle. B00103-10...
  • Page 18 Info hydraulic compression damping suspension determines the fork behavior. adjusting Turn the white all the way clockwise. screw — Info Adjusting is located end of the upper screw leg. left fork compression damping is located in the left fork (white adjusting screw).
  • Page 19 Guideline damping Rebound Comfort 20 clicks Standard 15 clicks Sport 10 clicks payload Full 10 clicks Info damping; Turn clockwise to increase turn counterclock- damping. wise to reduce Preparatory work motorcycle Lean the the side stand. — Main work Loosen bleeder screws —...
  • Page 20 position. Press the dust boots back into their normal — Remove oil. excess — Finishing work Position the fork protector. ('— — motorcycle from the lift stand. Remove the (“> clamp. Remove takeoff screws leg. protection Remove left fork Push the fork screws —...
  • Page 21 Info caliper Make that you do not press the brake sure against spokes pushing backthe brake when pistons. Do not operate the hand brake lever when the brake caliper is removed. Loosen rotations. several screw Loosen screws push spindle Press the wheel out of the axle on screw...
  • Page 22 FORK, TRIPLE CLAMP triple clamp Loosen of the both sides. Remove screws legs the fork from the bottom. protector Remove Take off the fork from above. screws GO00729-10 Installing legs the fork position Slide the fork protector from above and it.
  • Page 23 tighten Position the wheel speed Mount and sensor. screws Guideline Screw, speed wheel 6 Nm (4.4 sensor G00727-11 line, wiring harness, clamp. Position the brake Mount and tighten screws GO00726-10 Warning Danger of accidents Oil brake discs grease braking reduces the effect.
  • Page 24 Operate the front brake and compress the fork few times firmly. legs straighten. &” Thefork Tighten screws Guideline Screw, (11.1 fork stub 15 Nm G00725-12 Info operations legs. both fork same on Condition The fork legs have been removed. Make present note of the state of rebound...
  • Page 25 leg. Unclamp fork Drain the fork oil. 202309-10 clamp. Unclamp fork with the axle Info jaws. Use soft Slide the tube down. outer spring special hexag- Pull the downward. Mount the tool part. onal Open end wrench (T14032) (=* 299) 202310-10 Info ©...
  • Page 26 Clamp fork with the axle clamp. Guideline jaws. Use soft cartridge. Remove of the screw Info Place container underneath oil will out in most cases. G00853-11 cartridge. Removethe 202315-10 Remove dust boot 202115-13 ring Remove lock Info ring The lock beveled end where screwdriver applied.
  • Page 27 sliding bushing Remove upper — Info Without using tool, pull slightly the stack apart by hand. sliding bushing Take off lower — ®. ring Take off support — ring Take off seal — sopioa.i2| ring Take off lock -— ©. Take off dust boot leg.
  • Page 28 Check the tube for damage. outer there is damage: » Change tube. outer — 202112-10 sliding bushings. Check the surface of the sliding layer If the bronze-colored layer under the » is visible: Replace sliding bushings. — ® 200665-10 spring length. Check the Guideline Spring length...
  • Page 29 ©. ring Grease push on seal (T14034) (* 280) Lubricant Info Sealing lip upward. downward, open side support ring Push special Remove the tool. Sand the edges of the sliding bushings with 600 grit sandpa- bushings. then clean and per; grease Fork oil (SAE 4) (48601166S1)("...
  • Page 30 ring Mount lock Info ring The lock must engage audibly. Mount dust boot B03933-10 Assemble the individual components that belong together. Info Compression dampingside: cartridge with additionaloil adjuster, holes white axle clamp marked L. cartridge Rebound damping side: without additionaloil adjuster, clamp holes,...
  • Page 31 special cartridge; of the spe- Mount tool remove cial tool. Support (—" tool (T14026S1) 298) Pull piston spring. pin again. out the rod. Mount the Mount the cartridge special spring Pull with tool. Pull the downward slide the special tool hexagonal piece.
  • Page 32 vertically. Clamp fork — Fill with fork oil. — (SAE 4) Fork oil fork 635 ml Fork oil (21.47 oz.) (48601166351) 279) 202320-10 upward. Push the outer tube Clamp triple clamp. fork in the of the lower area Clamping (T14038)("= 299) stand preload adjuster.
  • Page 33 Turn counterclockwise the number of correspond- turns — leg type. to the fork Guideline Spring preload Adjuster Preload Comfort turns Standard 5 turns Sport 5 turns payload 8 turns Full Alternative 2 Warning Danger of accident Modifications to the suspen- setting seriously handling...
  • Page 34 possible easily It must be the handlebar move over steering entire range. There should be detectable detent positions. positions If detent detected: » Adjust steering bearing play. (© head — steering bearing adjust Check the head neces- — sary. Finishing work motorcycle Remove the...
  • Page 35 © triple clamp, On the there holes distance of upper each other. (0.59in) Hole distance © support placed The holes the handlebar distance of from the center. (0.138 in) Hole distance positions. The handlebar be mounted in 4 different In this 401454-11 posi- way, the handlebar...
  • Page 36 Preparatory work Remove the headlight mask with the headlight. ( — ~ 128) — Remove the seat. (=" — Main work tie(s). Removethe cable — Remove Take off the side screws cover. — Remove the cable tie(s). — Remove screw —...
  • Page 37 Expose position of the the cable accelerator sensor. ©. plug-in Disconnect connector — G00707-10 Remove screws Remove the combination instrument upwards out of the holder and hang theside. Loosen screw — GO0709-10 Remove screws — Take off hand guard. GO00710-10 Remove screws —...
  • Page 38 © grip position from Pull throttle and accelerator sensor — the handlebar. G00712-10 © grip position Position throttle and accelerator sensor the handlebar. “ Catch engages in driver GOO0713-10 tighten Mount and screws — Guideline grip Screw, throttle 3.5 Nm (2.58 @&...
  • Page 39 plug-in Join connector wiring position Route the harness of the accelerator sensor without tension. G00707-10 tie(s). Mount the cable Position the combination instrument in the holder. tighten Mount and screws Guideline Remaining 4 Nm screws, chassis tighten Mountand screw Guideline Remaining 4 Nm screws,...
  • Page 40 Secure the cables with the cableties. — G00703-10 Finishing work headlight headlight. Install the mask with the (-" 129) -— headlight setting. Checkthe 127) — engine electronics control unit. (© 236) Reset the — Program position (~~ p. 217) the gear sensor.
  • Page 41 right. Remove theleft and screws engine guard Pull the forward out of the holders and remove GOO0755-11 Slide engine guard into holders at the rear. engine guard. tighten Position the Mount and screws Guideline Remaining 10 Nm (7.4 screws, chassis GO0755-10...
  • Page 42 Caution injury incorrectly. Risk of Parts of the shock absorber will if the shock absorber is detached move around highly compressed nitrogen. The shock absorber is filled with description provided. Please follow the — Info high-speed setting compression The effect of the in fast of the shock absorber.
  • Page 43 9.3 A d j u s t i n g the r e b o u n d d a m p i n g of the a b s o r b e r , adjusting clockwise with screwdriver up to Turn screw —-...
  • Page 44 Preparatory work Raise the motorcycle with lift stand. (~— — Main work possible Measure the distance vertical between the — — — axle and fixed point, example, mark rear rear fairing. ©. Note down the value dimension — 400988-10 Finishing work motorcycle from the lift stand.
  • Page 45 ® Measure distance wheel unloaded. ("" rear holding motorcycle, With another person rider, wear- protective clothing, sitting full sits the seat in a normal position (feet footrests) and bounces up and down times. “ wheel suspension levels out. rear Another person the distance betweenthe now measures rear...
  • Page 46 Guideline Spring preload (0.79in) Info Depending riding the static sag and/or the sag, spring increase may be necessary to decrease the preload. Tighten retaining ring Finishing work ('— Install the shock absorber. (= p. 74) Mount the side cover. (“4 Mount the seat.
  • Page 47 Preparatory work Raise the motorcycle with the work stand. (— — ( = ~ Removethe seat. — Take off the side ( — cover. — Main work Remove screws — Remove the battery cover. Detach connector fairing. Lift the rear Remove screws —...
  • Page 48 Loosen screw Remove screw Remove screw Loosen screws — Swing upwards. rear ©. Lift off the shock absorber — rae) ‘: Main work Insert shock absorber from above. — Lowerthe rear. — tighten yet. Mount butdo screw Guideline Screw, top (33.2 45 Nm Loctite®243TM...
  • Page 49 Guideline Screw, top (33.2 45 Nm Loctite®°243TM shock absorber tighten Mount and screw Guideline (18.4 Screw, fuel 25 Nm Loctite®243TM tank, bottom tighten Mount and screw Guideline fuel (18.4 Screw, 25 Nm Loctite®243TM tank, bottom fairing. Lift the rear tighten Mount and screws Guideline...
  • Page 50 9. 1 1 S e r v i c i n g t h e shock Finishing work Mount the side cover. — Mount the seat. — Remove the motorcycle from the work stand. ("= — € absorber, Caution injury incorrectly.
  • Page 51 spring retainer Remove spring retaining ring adjusting Takeoff with the ring Bem, 201272-10 Preparatory work spring. Removethe (—" Main work damping Establish and the current of the rebound note state compression damping. Completely adjusters open the of the rebound and compression damping.
  • Page 52 piston oil. Remove the rod. Drain the remaining — 201278-10 compression adjuster spring, Remove Remove the sleeve, — piston. 201279-10 Preparatory work spring. ("" Remove the — damper. (~~ p. 49) Dismantlethe Main work the piston joint Clamp rod with the heim vise.
  • Page 53 supporting plate Remove and rebound shim stack — together with piston Info Thread the rebound shim set screwdriver and set on a parts down together. compression supporting plate Remove shim stack with — Info compression Thread the shim stack screwdriver on a and set the parts...
  • Page 54 piston Measure the diameter of the rod. Piston rod Diameter 17.95 0.7067 specification If the is not reached: » Change piston rod. — Measure the run-out of the piston rod. Piston rod 0.03 0.0012 Run-out <= If the measured value is specified greater than the...
  • Page 55 © Remove seal both sides. — 200578-10 ring Remove lock both sides. — 200579-10 special joint Place tool underneath and press out the heim — with special tool Pressing (T1207S) (\— 297) tool special push joint Place tool underneath and the heim —...
  • Page 56 ring Mount both sides. and grease seal — (T158) (© 280) Lubricant 200578-11 bushings joint. Press in both collar of the heim — Preparatory work damper. Check the (" p. 51) — Main work the piston joint Clamp rod with the heim vise.
  • Page 57 piston plate using Sand both sides of the surface 1200- on a grit sandpaper. piston. Clean the piston. Assemble the Guideline Piston from above View Piston from below View 201270-10 Mountthe rebound shim stack with the smaller shims fac- ing upward. supporting plate Install ©.
  • Page 58 Main work compression adjuster. spring Push the and sleeve onto piston. Mount the tighten compression adjuster Mount and Guideline Compression adjuster M26x1 30 Nm (22.1 201279-11 tighten Mount and screw Guideline Filling port (10.3 M10x1 14 Nm screw 201277-11 Clamp using jaws.
  • Page 59 ring push ring Install the seal it under the bearer groove. ring Mountlock Info Do not scratch the inner surface. piston ring Pull that the seal retainer rests against ring. the lock locking damper cartridge. Mount of the Bleed fill the damper.
  • Page 60 Guideline damping Rebound Comfort 20 clicks Standard 15 clicks Sport 10 clicks payload Full 10 clicks Alternative Warning Danger of accident Modifications to the suspen- setting seriously handling sion alter the char- acteristic. suspension setting Extreme modifications to the handling serious deterioration in the cause a characteristic and overload...
  • Page 61 photo. Place the control lever shown in the — /“ The External tank contro! leveris Closed, Damper Vacuum, Oil reservoir Vacuum. Operate the On/Off switch — “ pump process starts. vacuum /“ Pressure gauge falls specified value. [<0 20027110] “ specified falls to the value.
  • Page 62 specified When the value, pressure gauge reaches turn Oil reservoir control lever to Vacuum. Guideline 0 bar specified “ gauge falls to the value. vacuum 4 mbar specified value, When the pressure gauge reachesthe vacuum Equalize turn the Oil reservoir Pressure.
  • Page 63 Info floating piston positioned exactly must be this point when the fully extended; otherwise, damage during compression will of the shock absorber. occur Remove the special tool. Remove adapter from connection of the vacuum pump. Info damper filling high- Hold the port thatthe point.
  • Page 64 Info regulator Watch the pressure dial. specified Make that the damper is filled to the sure pressure. ©. filling using Close the port handle screw © Close spigot and take the damper special tool. out of Tighten filling port screw. Guideline reservoir Screw,...
  • Page 65 Alternative 2 Warning Danger of accident Modifications the suspen- setting seriously handling sion alter the char- acteristic. suspension setting Extreme modifications serious deterioration in the handling cause a components. characteristic and overload Only make adjustments within the — range. recommended making adjust- Ride slowly...
  • Page 66 » Danger of burns The exhaust system gets very hot when the vehicle is driven. before performing Allow the exhaust system to cool down any work the vehicle. Preparatory work Removethe seat. — Take off the side ("" cover. — Main work Remove cable ties —...
  • Page 67 Remove screw — Take off the manifold. — Main work Position the manifold with the seals. Position the spacer. — tighten Mount nuts — Guideline Nut, manifold 20 Nm (14.8 Copper paste cylinder head Position the exhaust clamp. Tighten screw —...
  • Page 68 Position the exhaust heat guard. ©. tighten Mount and screws — Guideline Screw, exhaust 8 Nm (5.9 Loctite®243TM heat shield Finishing work Mount the side ( © " cover. — Mountthe ( — seat. — Warning Danger of burns The exhaust system gets very hot when the vehicle is driven.
  • Page 69 Remove screws Remove the main silencer. /G00742-13 Position the main silencer. Mount and tighten screws Guideline Screw, (18.4 main silencer 25 Nm holder /G00742-14 tighten Mount screws Guideline fairing (3.7 Rear 5 Nm screw clamp. Position the exhaust ©. Tighten screw Guideline Screw,...
  • Page 70 Preparatory work Remove the seat. — Main work Remove screws — Remove the part of the air filter box upper — Note Engine damage Unfiltered intake air has negative effect engine. the service life of the engine Dust and dirt will enter the without air filter.
  • Page 71 Preparatory work Removethe seat. ( ~ ~ — ( — Take off the side cover. — Main work Remove screws — Take off the voltage regulator and hang to the side in — energized state. Remove screws — Remove screws —...
  • Page 72 Disconnect connector — Raise the air filter box at the rear. — Takeoff the air filter box. — Main work Position the air filter box. tighten clip Mount and hose — tighten Mountand screws — Guideline box, Screw, filter 6 Nm (4.4 frame Route...
  • Page 73 Plug connector — GO00741-12 Finishing work Mount the side cover. — Mount the seat. —...
  • Page 74 Danger highly Fuel Fire hazard flammable. The fuel expands in the fuel tank when escape if overfilled. warm vicinity cigarettes. refuel the vehicle in the of open flames engine refueling. Switch spilled; particularly that fuel is parts of the vehicle. Make sure spilled, wipe...
  • Page 75 Pull strap and raise the of the seat at the rear same — time. Pull back the seat and lift it off. — Hook slot of the seat onto press the downward and at the time push it forward. screw rear same —...
  • Page 76 Main work ©. Attach the side it in and engage cover area area — tighten Mount and screws — Guideline side (3.7 Screw, 5 Nm cover Repeat operations opposite side. Finishing work ("= Mount the seat. — Danger Fire hazard Fuel highly flammable.
  • Page 77 Thoroughly plug-in using connection of the fuel line clean the compressed air. Info Under circumstances should dirt into the fuel enter line. Dirt in the fuel line clogs injection valve! plate Press the small metal and disconnect fuel hose con- nection 302037-10 Info...
  • Page 78 Danger highly hazard Fuel flammable. Fire the fuel tank warm and escape ifoverfilled. The fuel expands when vicinity cigarettes. notrefuel the vehicle flames open Switch engine refueling. particularly parts fuel spilled; Make sure that n o vehicle. — immediately. spilled, wipe fuel specifications refueling.
  • Page 79 engine Start the and check the response. — Finishing work (© Install the air filter box. Mountthe side cover. — Mountthe (— seat. — Warning poisoning Fuel Danger poisonous health hazard. clothing Avoid skin, eye and contact withfuel. Immediately swallow fuel. doctor if you consult inhale...
  • Page 80 Main work Remove screws — fairing. Lift the rear — Remove screws — & Remove bothsides. screws —- Swing upward rear secure — G00743-12 and take off the splash protector. Remove screws — GO00747-10 Remove screws — Pull the fuel pump. —...
  • Page 81 Disconnect both fuel hose connections plug-in Disconnect Remove fuel pump. connector clamps Remove hose Remove fuelfilter. Mount the fuel filter. ® points Arrow from the fuel away pump. clamps Mount hose plier (60029057000) ("* Hose clamp 286) © locking Press mechanism both sides.
  • Page 82 Position the fuel pump. tighten Mount and screws Guideline Screw, fuel pump 4 Nm G00748-10 splash tighten Position the protector. Mount and screws Guideline Remaining 4 Nm screws, chassis GO0747-10 Position the end. rear &) Mount and tighten both sides. screws Guideline Screw,...
  • Page 83 Danger hazard Fuel is highly flammable. Fire fuel expands in thefuel tank when if overfilled. escape warm flames vicinity cigarettes. Do not refuel the vehicle open engine Switch for refueling. spilled; particularly parts Make that fuelis of the vehicle. sure fuel is spilled, wipe...
  • Page 84 & both sides. Remove screws Swing upward rear secure and take off the splash protector. Remove screws GO0747-10 Remove screws Pull the fuel pump. Disconnect both fuel hose connections Unplug Remove fuel pump. connector connecting Connect fuel pump, both fuel hose connec- tions Plug...
  • Page 85 ©. Position splash protector. tighten Mount and screws — Guideline Remaining 4 Nm screws, chassis Position the end. rear — Mount and tighten both sides. screws — Guideline Screw, fuel 25 Nm (18.4 Loctite®243TM tank, bottom fairing. Lift the rear —...
  • Page 86 — Warning Danger accidents Non-approved impact handling non-recommended tires and wheels character- istic. Only approved by KTM with the corresponding speed tires/wheels index. — Warning accidents Danger Newtires have reduced road grip. surface tires is roughened. contact on new riding alternating angles.
  • Page 87 DOT number. Thefirst two indicate the week of digits manufacture the last the year of manu- facture. changed KTM recommendsthatthe tires be after 5 latest, regardless HO1144-10 years at the of the actual state of wear. If the tires than 5 years old: are more »...
  • Page 88 damage, cracking, Checkthe front and brake discs for rear — deformation. damage, cracking, If the brake disc exhibits deforma- » tion: Change the brake disc. — Warning Danger of accidents Incorrectly spokes impair handling tensioned characteristic and result in sec- ondary damage.
  • Page 89 Info spoke imbalance, spokes A loose wheel which leads to loose short time. can cause more tight, they If the spokes break due to local overload. spoke regularly, especially Check the tension motorcycle. on a new Check the axial run-out and radial run-out of the rim. —...
  • Page 90 Danger Damaged of accidents brake discs reduce the braking effect. Always lay the wheel down in such way that the — damaged. brake disc is Holding wheel, spindle. the front withdraw the Take the wheel front wheel out of the fork. $00644-10 Info pull...
  • Page 91 spindle. Clean and the wheel grease Long-life ( “ 280) grease fork, position it, Jack up the front wheel into the and insert the spindle. wheel linings correctly positioned. ” The brake Mountand tighten screw Guideline Screw, front wheel M24x1.5 45 Nm (33.2 spindle...
  • Page 92 Removing 13.7.1 wheel rear Preparatory work motorcycle Raise the with lift stand. — Main work pull speed of the Remove wheel screw sensor — hole. caliper Press the brake onto the brake disc hand in order to — push piston. backthe brake adjuster Remove nut...
  • Page 93 Warning braking installing Danger of accidents There is effect to start with at the brake after rear rear wheel. going point. Actuate the foot brake several times before ride until feel firm pressure on a -— Main work dampers. Check the hub rubber ("—...
  • Page 94 Check the chain tension. ( — — Changing 13.7.3 brake disc rear Info changed, linings changed. If the brake discs the brake also be must Preparatory work Raise the motorcycle with lift stand. ( ~ ! — Remove the wheel. ( ©...
  • Page 95 Lean the motorcycle the side stand. — Shift gear to neutral. — upward Push the chain distance from the chain slid- — ©. ing guard and determine the chain tension Info The upper chain section must be taut. Chain always Repeat this wear...
  • Page 96 Main work Loosen — Loosen nuts — © Adjust by turning adjusting the chain tension screws — right. the left and Guideline (0.2 in) Chain tension adjusting right Turn the left and that the screws markings the left and right adjusters chain position...
  • Page 97 Main work idle. Shift the transmission — sprocket engine sprocket Check the rear wear. — If the sprocket engine sprocket rear worn: » Change the power set. — Info engine sprocket, sprocket, and chain rear always replaced together. should 100132-10 ©.
  • Page 98 sliding piece Check the chain wear. pins If the lower edge of the chain is in line with below » sliding piece: the chain Change sliding piece. the chain — sliding piece Checkthatthe chain firmly seated. sliding piece If the chain is loose: »...
  • Page 99 Warning braking —— Danger of accidents Oil the brake discs reduces the effect. grease Always keep the brake discs free of oil and grease. — Clean the brake discs with brake cleaner when necessary. — Warning damage. Environmental hazard Hazardous substances environmental cause correctly...
  • Page 100 sprocket wheel workbenchwith the fac- rear on a rear — ing upwards spindle and insert the wheel in the hub. ©. play tight To check hold the wheel to turn rear —- sprocket with your hand. rear Info Measure the play the outside of the sprocket.
  • Page 101 HARNESS, B ATTERY WIRING Removingthe battery Warning injury Battery Risk of battery serious chemical burns. acid and gases cause batteries out of the reach of children. Keep — protective clothing safety glasses. Wear suitable — Avoid with battery acid and battery contact gases.
  • Page 102 HARNESS, WIRING BATTERY Remove screws — retaining battery Pull bracket of the forward and remove — battery Lift the up and out. — Info motorcycle discharged battery Never operate with battery. without In both electrical compo- cases, safety damaged. nents and devices The vehicle longer...
  • Page 103 Finishing work (“= Mount the seat. — 125) Set the clock. — Preparatory work ignition by turning ignition key Switch off the position OFF &. ("" Remove the seat. — Main work ©. Remove battery cover — Disconnect negative of the battery.
  • Page 104 Finishing work ("= Mount the seat. — (©) 125) Set the clock. — Warning Risk of injury Battery battery serious chemical burns. acid and gases cause batteries Keep out of the reach of children. — protective clothing safety glasses. Wear suitable battery battery Avoid...
  • Page 105 Main work battery charger battery. Switch Connect the to the the bat- — charger. tery battery charger XCharge-professional (00029095050) 282) Alternative 1 battery charger XCharge-professional (00029095051) (©= 283) 311910-10 Alternative 2 battery charger XCharge-professional (00029095052) (= 283) Alternative 3 XCharge-professional battery charger (00029095053)(—...
  • Page 106 engine Pull off the electronics control unit in area — hang side. Take off the terminal cover. — motorcycle Start the to check the function. ( ~ ~ p. 14) -— GO00722-11 voltage specified points. Measure the between the ‘yy —...
  • Page 107 Preparatory work Switch off the ignition by turning ignition key — position OFF &. Remove the seat. (© — Main work Remove cover — negative battery. Disconnect the cable of the battery ground Measure the between and the nega- current —...
  • Page 108 Warning Fire hazard Incorrect fuses overload the electrical system. required Only fuses with the ampere value. bypass repair Do not fuses. — Info housing relay The main fuse protects all power of the vehicle. It is of the starter next to consumers battery.
  • Page 109 Info containing The fuse box the fuses of individual power is located under the seat. consumers Preparatory work ignition by turning ignition key Switch off the — position OFF &. Remove the seat. (— — Main work Open fuse box cover —...
  • Page 110 (75011088015) (—= 243) Fuse Replace fuse in the fuse box that it is spare available if needed. functioning properly. Check that the power consumer -— Close the fuse box cover. — Finishing work Mount the seat. — Preparatory work ignition by turning ignition key Switch off the —...
  • Page 111 Diagnostics engine is located under the control unit. connector $02172-10...
  • Page 112 — approved been and recommended KTM. Only approved by tires/wheels KTM with the corre- sponding speed index. specified Maintain the tire air pressure. repairs performed profes- Service work and must sionally. safety system...
  • Page 113 again. warning lamp switched The ABS when goes out you start off. manually The button be used to switch ABS off (see Start- ing). Warning linings Danger of accidents Worn-out brake braking reduce the effect. linings replaced immediately. Ensure that worn-out brake Warning Danger of accidents...
  • Page 114 Not all brake tested and The structure and friction coefficient for KTM of the brake linings, and thus their brake greatly from that of original brake linings. power, may vary...
  • Page 115 spring caliper sliding Check that leaf in the brake — plate caliper correctly. in the brake support seated linings, insert the pin, Insert the brake the cot- mount — pin. Info Always change the brake linings pairs. Operate the hand brake lever repeatedly until the brake...
  • Page 116 Check the free travel of the hand brake lever. ( ~ — 113) — Adjust adjusting the free travel of the hand brake lever with — screw Info adjusting Turn the clockwise reduce free screw point away from the travel. The pressure moves handlebar.
  • Page 117 Warning Danger of accidents An insufficient brake fluid level will system fail. the brake cause specified specified drops marking value, If the brake fluid level below the the brake system leaking linings the brake down. are worn riding until the problem Check the brake system...
  • Page 118 Info spilt immediately Clean up overflowed brake fluid with water. Warning Skin irritation Brake fluid skin irritation. causes Keep brake fluid of the reach of children. safety glasses. protective clothing Wearsuitable — skin, clothing. Do not allow brake fluid to into contact with the the eyes come...
  • Page 119 Open shut-off valve Info Follow the instructions in the Owner's Manual of the bleeding device. ©. filling Ensurethatthe pressure is set pressure gauge © filling regulator Correct the pressure pressure neces- sary. Guideline Filling psi) 2... 2.5 bar pressure protection caliper Pull off of the brake...
  • Page 120 Warning Danger linings braking of accidents Worn-out brake reduce the effect. replaced immediately. linings Ensure that worn-out brake — Warning braking Danger of accidents Damaged brake discs reduce the effect. If the brake linings changed time, the brake lining carriers grind against the brake disc.
  • Page 121 Brake linings approved motorcycles. Not all brake tested and for KTM The structure and friction coefficient linings, greatly original linings. of the brake and thus their brake power, may vary from that of...
  • Page 122 Adjust the brake fluid level the MAX mark. — (© 278) Brake fluid DOT 4 / DOT 5.1 Mount the cap with the membrane. screw — Info spilt immediately Clean overflowed brake fluid with water. € Warning Danger of accidents The brake system fails in the overheating.
  • Page 123 & fittings cylinder foot brake Loosen — adjust position individually, the basic of the foot brake lever — accordingly. loosen and turn screw Info adjustment The range of is limited. The must screw screwed into the footrest bracket four at least turns.
  • Page 124 Warning Danger of accidents An insufficient brake fluid level will system fail. the brake cause drops marking, leaking linings If the brake fluid level below the MIN the brake system the brake down. worn Check the brake riding problem is eliminated. system and do not continue until the...
  • Page 125 Warning §kin irritation Brake fluid skin irritation, causes ~— Keep brake fluid out of the reach of children. — protective clothing safety glasses. Wear suitable -— allow brake fluid into with the skin, the eyes clothing. contact come — immediately Consult doctor brake fluid has been swallowed.
  • Page 126 Guideline Filling psi) 2... 2.5 bar pressure Pull off protection of the bleeder Connect the screw. bleeder bottle hose. Bleeding device (00029013100) ( " = 282) Open bleeder half turn. approx. screw Info Drain until fresh brake fluid emerges in the bleeder bot- tle hose without bubbles.
  • Page 127 Setting 16.1.1 the kilometers miles Info the unit changed, is retained accordingly. the value and converted setting according Makethe country. to the Condition motorcycle stationary. ignition by turning ignition key Switch position ON ©. Press the MODE button repeatedly until the ODO display mode —...
  • Page 128 ignition by turning ignition key Switch -— ©). position repeatedly Press the MODE button until the TRIP 1 modeis — active. Keep the SET button pressed. -— display The TRIP 1 0.0. set to 401445-01 Setting/resetting display 16.1.4 TRIP 2 Info trip The TRIP 2...
  • Page 129 Main work Unplug from the combination instrument. connector ED it from connector ED. Unlock remove Plug into connector ED the combination instrument. ignition by turning ignition key Switch position ON ©). repeatedly display Press the MODE button until the TRIP 1 mode is active.
  • Page 130 Adjust headlight ("= 128) range. — Preparatory work headlight setting. ( " > 127) Check the Main work adjusting adjust headlight Turn range. screw Guideline boundary light exactly between and dark must lower mark for motorcycle with rider (instructions apply Checking headlight setting).
  • Page 131 Main work plug-in Connect of the headlight of the connectors — signals. turn lighting functioning properly. Check that the — position headlight Remove the cloth from the fender and — mask. ‘i %~ Holding lugs headlight reach into the mask. ’...
  • Page 132 Main work protection Remove — of the reflector. Pull bulb socket — parking light Pull bulb out of the bulb socket. — parking light Insert bulb in the bulb socket. a new — Parking light (W5W / socket W2.1x9.5d) ("= 243) Insert the bulb socket in the reflector.
  • Page 133 spring Detach — headlight Remove bulb — headlight headlight housing. Insert bulb into the — Headlight / socket P43t) (~~ 243) headlight headlight using spring bulb in the bar. — protection Plug in the connector. Mount the cap. Finishing work Install the headlight mask with the...
  • Page 134 (690 Enduro R signal housing. Remove the of the turn screw on rear — headlamp carefully Tilt diffuser forward and takeit off. — signal lightly Press the turn bulb into the socket, turn it — 30°, counterclockwise about and take it of the socket.
  • Page 135 Preparatory work Switch off the ignition by turning ignition key position OFF &. Removethe seat. ( — — Disconnect the battery. ( = > 101) motorcycle (—= Raise the with the work stand. ("~ Take off the side cover. Removethe air filter box. (="...
  • Page 136 adjuster. Remove the chain Remove nut — spindle enough Pull out wheel to allow the wheel to be rear — pushed forward. possible Push the wheel forward and take the rear — sprocket. chain off the rear Info wheel fully removed.
  • Page 137 ignition Disconnect both plugs coils. — ®. engine Disconnect coolant temperature connector sensor — ® special spring clamps using Loosen the band tool. — Spring clampsplier (60029057100) ( — 286) band Pull off the hoses. — @® Unplug from the oil Remove connector pressure...
  • Page 138 fitting engine of the lower Remove bracket. — swingarm pivot. Remove of the screw — swingarm pivot engine. Pull the out far enough to release the — engine. Lower the — Info help assistant is useful in this step. engine sufficiently Make that the...
  • Page 139 jack special Removethe floor with the tool. jack (75029055000) ("= 292) Floor attachment G00769-10 engine Position the bearer. Mount and tighten screws Guideline Screw, engine bearer 45 Nm (33.2 frame tighten fitting Mount and Guideline Engine carrying 45 Nm (33.2 GOO768-11 Loctite®243TM screw...
  • Page 140 Plug ignition in both plugs of the coils. marking & Thecable with the white is connected to the ignition coil. outer Plug engine in the connector coolant temperature sen- © plug-in position of the Connect connectors gear sensor, position crankshaft and alternator.
  • Page 141 engine sprocket Mount the with the chain. tighten Position the lock washer and mount nut but do not yet. Position the wheel. rear Mount the chain adjuster and nut. adjusters Push the wheel forward that the chain rest rear ®. against tensioning tighten...
  • Page 142 ("" Perform theinitialization ( " " 236) run. Go for short test ride. using diagnostics Read out the fault memory the KTM tool. engine tightness. Check the for leak engine oil level. ( © 225) Check the 221) Checkthe coolant level.
  • Page 143 Draining engine 17.3.2 plug ring. Removetheoil drain with the seal magnet and plug O-rings. Remove with oil and the screen — @& plug O-rings. Remove with oil screen Completely engine drain the oil. Remove oil throttle — Take off the starter motor. —...
  • Page 144 Removing 17.3.5 the alternator cover Remove screws — Take off the alternator cover. & ©. gasket Take off alternator dowels cover remove Removing 17.3.6 the spacer Remove spacer — 305521-10 Removing position 17.3.7 the gear sensor Remove with the washers. screws —...
  • Page 145 Removing 17.3.8 the oil filter Remove screws — O-ring. Take off the oil filter with the cover — Removeoilfilter ring plier Lock (51012011000) ( — 284) ©. Remove screws — O-ring. Take off the oil filter with the cover — Removeoil filter —...
  • Page 146 Remove screw Info position Look through the hole to check that the hole of the balancershaftis visible. special Screwin tool Locking (77329010000)(4 294) screw <4 Removing spark plugs 17.3.11 spark plugs Remove — Spark plug (75029172000) ( " = 293) wrench 305516-10 Removing...
  • Page 147 bearing Pull the camshaft of the seats. timing Take the chain off the camshaft gear. Remove the camshaft. Remove screws — diagonally Loosen them. screws remove — Take off the cylinder head. — Removing piston 17.3.15 cylinder gasket Take off the head —...
  • Page 148 cylinder Take off the gasket base Info grooved pins remain in Ensure that the two place. Remove Take off the water pump screws cover. 305556-10 Remove screw impeller Remove water pump Take off the water pump seal. cover Info locating pins place.
  • Page 149 Hold the rotor with special tool Holding (75029091000) ( — = 293) wrench Info Make that the crankshaft is not blocked. sure locking edge Remove nut and the washer. special Mount the too! the rotor. (58429009000)(\— 284) Puller special Hold it tight using pull off the rotor...
  • Page 150 ring Take off lock -— ©. timing special Pull off the chain sprocket with tool — (59029033000) ("= 286) Puller Removing ignition pulse 17.3.20 generator Remove screws — Pull cable sleeve of the engine case. ignition pulse generator. Remove the Removing 17.3.21 the clutch...
  • Page 151 Removing spring 17.3.22 the spacer and spring Remove spacer the antihopping special Clamp clutch with tool Assembly (75029033000) (= 289) screws Info Apply special only; tool hand do not another tool. diagonally Loosen them with their screws remove spring springs. retainers and clutch Remove pressure cap ©.
  • Page 152 Info LH thread! special Remove the tool. — Gear segment (75029081000) (—" 292) antihopping Take out the clutch. — 205580-10 ©. stepped Remove washer — Remove half washers — Take off clutch basket ®. bearing supporting plate Remove needle — 305583-10...
  • Page 153 Removing primary 17.3.24 gear special Position tool Protection (75029090000)('* 293) Mount special tool (75029021000)(°* 289) Puller using special pull primary Hold it tool and off the gear turning screw special Remove the tools. ring Remove lock Takeoff the starter idler gear with the washers.
  • Page 154 shift 17.3.26 Removing shaft sliding plate locating Push from the shift drum away © Remove shift shaft with the washer. 305618-10 Removing shift locating 17.3.27 drum Remove screw © locking locating Press lever away from shift drum take off the shift drum locating.
  • Page 155 pins Remove and washers. Remove screws Take off the oil pump cover. © shaft Remove oil pump with the internal rotor. — Remove external rotor — ©. Remove screws — Take off the oil pump cover. © shaft Remove oil pump with the internal rotor.
  • Page 156 engine 17.3.30 Removing left case Remove screws — Swing engine theleft section of the case remove — engine fixing of the or screw arm. special Mount tool with suitable screws. — (75029048100) ("* 291) Puller Info marking Use the drill hole with 750.
  • Page 157 Removing 17.3.32 the transmission shafts Removeshift rail — Swing shift forks side. Removeshift drum Removeshift forks — e—iInfo pins place. Ensure that the remain in ring Removelock and the stop disk. 305641-10 Remove transmission shafts Info stop usually disk of the countershaft sticks to the bearing.
  • Page 158 Working right engine 17.4.1. section of the case Remove oil nozzle bearing bearing, Remove retainers of the main shaft bearing bearing. the countershaft of the shift drum sealing compound Remove any remnants of and clean the sec- engine thoroughly. tion of the case housing.
  • Page 159 engine After the section of the cooled, check that the case firmly bearings seated. Info bearings firmly cooling, If the seated after likely they engine that will rotate in the when case engine In this case, the be renewed. must warm.
  • Page 160 spring pis- plug with Remove and take pressure screw — @& valve out of the drill hole. sealing compound Remove any and clean the remnants sec- — engine thoroughly. tion of the case engine Warm the section of the case an oven.
  • Page 161 Guideline jet, piston M6x0.75 4 Nm Loctite®243TM cooling Mount the dowels. — through Blow compressed air all oil channels and check that — they clear. spring length Measure the of the oil regulator valve. pressure — regulator (0.9984in) Oil pressure valve 25.36 spring length...
  • Page 162 Removing bearing ring 17.4.4 inner crankshaft special Fix the crankshaft with tools in the vise. Separator plate, part (75029047050) (== 290) upper Separator plate, base (75029047051) (= 291) §302145-10 ©. special Heat the tool Guideline (302 °F) 150 °C (58429037043)(© 285) Puller ©...
  • Page 163 Info Hold the lower crankweb. connecting bearing. Take off the rod and Press the crank of the crankweb. 300138-10 © Press in the crank possible. obey. Info pressed © The crank that oil chan- must ®. aligned with oil channel the oil channels correctly aligned, the conrod...
  • Page 164 Position special with the heel at the bottom. tool pressing (75029047000) (' 290) Crankshaft tool Press the upper crankwebin possible. — Info applied The press mandrel must be above the crank pin. special Take the crankshaft out of the tool, and check the con- —...
  • Page 165 Place the drive wheel the crankshaft. — ©. “The dowelof the crankshaft fit in the drill hole must & ~“ punch The side of the drive wheel with the mark must assembly, be visible after and the side with the bevel be in with the crankweb.
  • Page 166 Measuring 17.4.10 axial clearance of crankshaft and balancershaft right engine Insert the crankshaft and balancer shaft in the casing. Info forget Do not the dowels. engine casing. Mountthe left tighten Mount and screws. Guideline 300126-10 Screw, engine 10 Nm (7.4 case engine Mount the dial gauge...
  • Page 167 Nikasil® Cylinder coating 17.4.11 Nikasil® protection layer coating procedure surface devel- oped by Mahle. The is derived from the materials used name procedure layer in this of nickel into which is embedded the particularly hard silicone carbide. important advantages Nikasil® coating of the most...
  • Page 168 Checking/measuring piston 17.4.13 ® special play piston rings Use the tool of the measure piston ring groove. Guideline ring Piston groove clear- 0.08 0.0031 < ance (59029041100) Feeler gauge ( « = 286) play specified greater than the value: » Change piston piston rings.
  • Page 169 Info piston Piston size is marked head. Checking piston ring 17.4.14 end gap Removethe piston ring from the piston. piston ring cylinder align piston. with the Place the Guideline edge Below the upper of the (0.39in) cylinder Measure end gap with feeler gauge.
  • Page 170 feeler gauge play between the exter- measure — engine nal rotor and the well betweenthe external case as internal rotor and the rotor. pump Clearance between 0.20 0.0079 exter- < engine nal rotor and case Clearance between exter- 0.20 0.0079 nal rotor and internal rotor (0.0016...
  • Page 171 Replacing autodecompressor 17.4.17 ring autodecompression Take the lock off the shaft and dispose 300107-10 autodecompression Pull the shaft from the camshaft. 300108-10 autodecompression spring. Disconnect the Loosen the together autodecompression with the screw remove spring autodecompression weight and the 300109-10 assembling, first autodecompression spring...
  • Page 172 installation 17.4.18 Preparingtiming chain tensioner for Fully timing compress the chain tensioner. Info requires This considerable force since the oil has pressed out. timing Release the chain tensioner. timing expands “ Without pressure, the chain tensioner fully. __200171-10 compensating piston Place two disks similar aids next to the...
  • Page 173 Checking timing assembly 17.4.19 ® 305601-10 Cleanall parts well. timing damage Check chain gear wear. If there is damage or wear: » Change timing gear/timing sprocket. chain chain -— timing tensioning damage Check chain rail wear. If there is damage or wear: »...
  • Page 174 Removing 17.4.20 the rocker arm spring Take shims of the valve retainers and them —- position. side according their normal built-in Remove screws — Screw suitable into the rocker shafts Pull screw the rocker shafts. Take off rocker — Changing camshaft bearing 17.4.21...
  • Page 175 bearing using special large camshaft Remove the tool (75029051000) ("— Pressing p. 291) tool Info special Brace the back of the tool with suitable tool 305669-10 bearing using special Remove the small camshaft tool bearing puller (15112018100) (-— 284) Internal Bearing puller (15112017000) (—...
  • Page 176 Removing 17.4.22 the valves springs using special Pretension the valve tool. spring (59029019000)(== Valve mounter 285) spring Insert for valve lever (78029060000) ("= 294) Remove the valve keys and release the tension the valve springs. spring spring. Remove the retainer and guide, Pull the valve down and out of the valve remove...
  • Page 177 Checking springs 17.4.24 valve springs Check the valve for fractures and (visual check). wear spring If the valve is fractured or worn: » Change spring. thevalve — spring lengths. Measurethevalve Valve spring length Minimum (without 42.3 (1.665in) spring cap) valve equal specified If the measured value does not...
  • Page 178 sealing Check of the valves. seat — sealing Valve seat width (0.063in) Intake 1.60 Valve sealing width seat 2.00 (0.0787in) Exhaust equal specified If the measured value does not value: » Machine the valve seat. — 302808-10 through Blow compressed air all oil channels and check that —...
  • Page 179 Installing 17.4.28 the rocker push Position rocker in the rocker shafts — Info tapped Make that the hole of the rocker shaft sure facing outward. The small drill hole and the flat surface must face upward. ©. Remove screw — 305667-10 tighten Mount...
  • Page 180 Take the clutch of the vise and clean workbench on a — with the outer clutch hub facing down. springs Take the inner clutch hub and release — clutch hub the outer 300121-10 facing Take off the clutch discs from the inner clutch hub. —...
  • Page 181 push flat surface and check for run-out. Place the clutch on a — If there is run-out: » Change the clutch push rod. — length springs Check the of clutch — spring length Clutch 31.5... 33.5 (1.24 1.319 spring length is shorter than specified: If the clutch...
  • Page 182 Preassembling antihopping 17.4.31 clutch Thoroughly facing oil the clutch discs. — support ring pretension ring Push the and the to the — clutch hub. outer Info pretension ring must be installed that it is flush ® edge support ring. with the inner facing Position the trimmed clutch disc with the...
  • Page 183 Checking 17.4.32 shift mechanism 305597-10 ©) damage Check shift forks (see (visual check). wear — damage If there is or wear: » Change the shift fork and gear wheel pair. — Check shift grooves shift drum wear. — If the shift groove is worn: »...
  • Page 184 deep present: notches » Change sliding plate. -— guide pin Check for looseness and wear. — guide pin If the is loose and/or worn: » Change sliding plate. -— 182) Preassemblethe shift shaft. — play sliding quad- Check between the plate and the shift —...
  • Page 185 Disassembling 17.4.34 main shaft 306232-10 facing Fix the main shaft in the vise with the geared downward. Guideline jaws. Use soft second-gear Remove stop disk fixed gear ©. sixth-gear Removethe idler gear split bearing Removethe needle stop disk ring Remove lock Info Open ring...
  • Page 186 Disassembling 17.4.35 the countershaft 306233-10 facing Secure the countershaft in the bench vise with the toothed end downward. Guideline jaws. Use soft first-gear Remove stop disk idler gear bearing Remove needle stop disk ©. fifth-gear sliding ring Remove and lock gear Info Open...
  • Page 187 305674-10 bearings Check needle damage wear. damage If there is or wear: » Change bearing. the needle — © pivot points damage Check the of main shaft and countershaft wear. damage If there is or wear: » Change the main shaft and/or countershaft. —...
  • Page 188 Check stop disks damage wear. — If there is damage or wear: » Change stop disk. — rings repair job. lock in every — © bearing damage Check bush wear. — damage |f there is or wear: » Change bearing bush.
  • Page 189 Mounting ring (75029005000) ( " — 288) tool for lock Position lock ring special tool push down with sleeve & The lock ring engages in the groove of the transmission shaft. third/fourth-gearsliding facing Push with the small gear wheel downward. gear —...
  • Page 190 bearing protruding second-gear idler gear the countershaft with the collar fac- Mount bush and the — downward. stop Mount disk — special Position tool the transmission shaft. — Mounting ring (75029005000)(== 288) tool for lock Position lock ring special push down with sleeve tool —...
  • Page 191 Checking drive 17.4.39 starter 305600-10 bearing damage Check the gear mesh and of starter idler gear wear. -— damage If there is or wear: » Change the starter idler gear and/or needle bushing. — & Check the gear teeth and bearing torque limiter...
  • Page 192 Checking 17.4.40 freewheel primary turning Insert the freewheel in the gear gear — primary clockwise; do not twist! gear locking Check the action of the freewheel gear — primary If the does clockwise if it does not turn gear » lock counterclockwise: 190) Remove the freewheel.
  • Page 193 expansion ring Install the — lugs expansion ring Make that all of the locate in the sure — slits of the freewheel. Info screwdriver to them in. necessary, use a ease 300130-10 © ring pliers Insert the lock into the groove with suitable —...
  • Page 194 Mount upper shift fork middle shift fork and lower shift fork Info assembly lift For easier of middle shift fork sliding gear of the third/fourth gear. Mountshift drum Hang shift forks into the shift drum. Mountshift rail — operation. Check the transmission for smooth ©.
  • Page 195 instatiting crankshaft balancer shaft special Mount tool the alternator side of the crankshaft. ¢ Protecting (75029080000)(* 292) sleeve special Mount the tool the clutch end of the crankshaft. Protecting sleeve (75029080050)(** 292) special Mount tool the balancer shaft. Protection (58529005000) ('" 285) bearing Push the crankshaft into the...
  • Page 196 Guideline engine Screw, M6x80 10 Nm (7.4 case © tighten Mount yet. but do not screw — Guideline Screw, engine M6x70 10 Nm (7.4 case tighten Mount but do not yet. screws — Guideline Screw, engine M6x30 10 Nm (7.4 case tighten yet.
  • Page 197 shaft. Mount the and internal rotor the oil pump — engine Position the external rotor in the with the bevel case -— facing inward. Mountoil pump shaft with internal rotor — Oil the parts. — 305631-10 Position the oil pump cover.
  • Page 198 Installing locating 17.5.6 shift drum locking position locating. Press lever down and shift drum — Info The flat surfaces of the shift drum locating symmetric. locking Release the lever. tighten Mount and screw — Guideline Screw, shift 10 Nm (7.4 Loctite®243TM locating drum...
  • Page 199 ©. Position freewheel gear 305616-11 bearing Mount the needle torque limiter with the washer. ring Mount lock Mountthe idler gear with the washer. starter ring Mountlock Installing primary 17.5.9 gear properly. Ensure that the woodruff is seated primary Mount gear Info Turn freewheel gear backwards and forwards...
  • Page 200 Mountclutch basket — Info Turn the clutch basket and oil pump gear wheels back- slightly help wards and forwards them mesh more easily. sharp edge facing Mount half washers with the outward. — Info assembly. Grease the half washers ease Position stepped washer...
  • Page 201 Mountclutch throw-out Position pressure cap tighten Install and with the spring retainers and screws clutch springs. Guideline Screw, clutch spring 8 Nm (5.9 Ibf Info springs coding. Ensurethat all clutch have blue color ®. special Remove tool Assembly (75029033000) ('" 289) screws Installing...
  • Page 202 Position the clutch cover. tighten Mount but do yet. screws Guideline Screw, clutch M6x30 10 Nm (7.4 cover tighten Mount butdo yet. screw Guideline Screw, clutch M6x35 10 Nm (7.4 cover 305587-10 tighten Mount crisscross pat- screws screws tern. Guideline Screw, (7.4 clutch...
  • Page 203 Installing timing chain rails 17.5.15 timing securing guide Position the chain ignition pulse & generator cable is routed in the cable timing securing guide. duct of the chain timing tensioning Position the chain rail from above. bushing timing securing Insert the support into the chain...
  • Page 204 special Hold the rotor with tool Holding (75029091000) (‘ = 293) wrench tighten locking edge Mount and with the washer. Guideline Rotor M18x1.5 100 Nm (73.8 Adjusting position distance 17.5.17 crankshaft sensor Adjust position the distance between the crankshaft sensor using special and the conductive elementof the...
  • Page 205 impeller Mount water pump — ©. tighten Mount and screw — Guideline Screw, (7.4 10 Nm water Loctite®243TM pump wheel the water pump seal cover — 305559-10 Position the water pump cover. — Mountand tighten screws Guideline Screw, 10 Nm (7.4 water pump cover...
  • Page 206 ©. sealing compound Apply thin layer area — Loctite® 5910 Place the cylinder base gasket — Info grooved pins correctly. Make seated sure 305553-10 engine opening timing Cover the with cloth. Thread the case — piston pin. chain through the chain shaft. Mount the Info clarity, following steps...
  • Page 207 Removethe cloth. timing chain tensioned. Push the cylinder Keep down care- fully grooved pins and let the engage. Installing cylinder head cylinder gasket. head Info grooved pins correctly. Make seated sure cylinder Mount the head. tighten Mount and with the washers. screws Guideline Cylinder...
  • Page 208 Installing 17.5.22 camshafts timing chain the camshaft. Push the camshaft over bearing into the seat. & Thecrankshaft is at dead center. ~“ The middledrill hole of camshaft and drill hole cylinder head aligned. ©. support plate tighten Position the camshaft Mount and screw Guideline...
  • Page 209 special timing push Remove tool to screw timing chain tensioner toward the chain. timing Release device for chain tensioner (77329051000) (<3 294) & timing chain tensioner unlocks. ©. tighten Mountand screw Guideline Screw, unlocking (7.4 M10x1 10 Nm timing chain ten- sioner special...
  • Page 210 Adjusting 17.5.25 the valve clearance Remove screws Info Make that the crankshaft is dead center. sure 305535-10 ©. Screw suitable into the rocker shafts screws Remove the rocker shafts and take off the rocker arm. 305536-10 according Remove shims and set them down to the instal- position.
  • Page 211 Installing spark plugs 17.5.26 tighten spark plug using special Mountand tool. Guideline Spark plug inside M12x1.25 18 Nm (13.3 Spark plug (75029172000) (=" 293) wrench tighten spark plug using special Mount and tool. Guideline Spark plug outside M10x1 11 Nm (8.1 "...
  • Page 212 Insert oil filter O-ring Oil the of the oil filter it with the oil cover mount filter cover. tighten Mount and screws Guideline (4.4 Screw, filter 6 Nm cover Installing position 17.5.29 the gear sensor position O-ring. Mount gear with the sensor engages in drill hole tighten...
  • Page 213 Installing 17.5.31 the alternator cover Apply sealing lightly in the of the cable sleeve. compound area Loctite® 5910 @Pand gasket place. Mount dowels alternator cover Position the alternator cover. tighten Mount screws Guideline Screwin alternator 10 Nm (7.4 cover Mount and tighten screws Guideline...
  • Page 214 © O-rings. Position the oil with screen tighten plug O-ring. Mount with the screw Guideline Plug, (11.1 M20x1.5 15 Nm screen O-ring Grease the mount the starter motor. Long-life ("~ 280) grease tighten Mount and oil throttle Guideline Screw, 10 Nm (7.4 starter Loctite®243TM...
  • Page 215 Warning Skin irritation Brake fluid skin irritation. causes Keep brake fluid out of the reach of children. — protective clothing safety glasses. Wear suitable -— allow brake fluid into with the skin, the eyes clothing. contact come — immediately Consult doctor brake fluid has been swallowed.
  • Page 216 Warning Skin irritation Brake fluid skin irritation. causes brake fluid children. Keep the reach of protective clothing safety glasses. Wearsuitable allow brake fluid into with the skin, clothing. contact the eyes come immediately if brake fluid has Consult doctor been swallowed. plenty Rinse the affected with...
  • Page 217 Info Clean up overflowed spilled immediately brake fluid with water.
  • Page 218 Preparatory work Raise the motorcycle with lift stand. ( — — Main work Remove screw — engine Take off the sprocket Remove screw cover. — > GO00696-10 plug-in Disconnect connector Remove cable tie(s). — Expose the cable. -— with the washers. Remove screws —...
  • Page 219 ©. plug-in Join connector — tie(s). Route the cable without tension and with cable secure — engine sprocket Position the cover. — Mountand tighten screw — Guideline Remaining 10 Nm (7.4 screws, chassis tighten Mount and screw — Guideline Remaining 25 Nm (18.4 screws,...
  • Page 220 Warning Danger scalding During motorcycle operation, gets very hot and is under pressure. the coolant cooling engine radiator, system components Do not open the the radiator hoses other if the cooling operating temperature. system Allow the cooling system and the engine to cool down before...
  • Page 221 Stand the motorcycle its side stand horizontal surface. on a — Remove radiator cap — Refill with coolant. — Coolant ("" 278) Completely fill the radiator with coolant. -— Mountradiator -— compensating Remove the tank cover — figure. Add coolant the level shownin the —...
  • Page 222 Warning Danger poisoning Coolant is toxic and health hazard. Keep coolant out of the reach of children. skin, clothing. Do not allow coolant to into with the the eyes and contact come immediately if coolant is swallowed. Consult doctor immediately plenty Rinse the affected with...
  • Page 223 Warning Danger scalding During motorcycle operation, gets very hot and is under pressure. the coolant radiator, radiator cooling components engine Do not hoses other system if the open -— cooling operating system temperature. Allow the cooling and the engine to cool down before you open the radiator, the radiator hoses system...
  • Page 224 Warning Danger scalding During motorcycle operation, gets and is under pressure. the coolant very hot engine radiator, cooling system components Do not open the the radiator hoses other if the cooling operating system temperature. Allow the cooling system and the engine cool down before radiator,...
  • Page 225 Stand the motorcycle its side stand horizontal surface. on a Refill with coolant. (=" 278) Coolant 1.20 | Coolant (1.27 qt.) Completely fill the radiator with coolant. Mountradiator & compensating of the Remove tank. cover figure. Add coolant to the level shown in the Mount of the compensating...
  • Page 226 402053-60 Oil circuit of force pump screen Force pump Oil filter regulator Oil pressure valve Timing chain tensioner Oil nozzle for rocker lubrication Transmission Clutch piston cooling Oil nozzle for Oil filter bearing lubrication Oil nozzle for conrod Oil circuit of suction pump screen Suction pump...
  • Page 227 Info engine engine oil level must be checked whenthe warm. Condition engine operating temperature. Preparatory work motorcycle upright Stand the horizontal surface. on a — Main work engine Check the oil level. — Info switching engine, After off the wait minute before checking level.
  • Page 228 banjo sealing rings. Position the bolt with the connector and — Mount and tighten banjo bolt. Guideline Banjo bolt M10x1 8 Nm (5.9 adapter (77329006000)( — " 293) pressure special Connect the pressure tester tool without the — plate. testing (61029094000)(= 287) Pressure...
  • Page 229 Finishing work engine 225) Check the oil level. — engine (> 227) Drain the oil. — ("*° 228) Removetheoil filter. — Clean the oil 229) screens. — (© 229) Install the oil filter. engine (<= 230) Fill with oil. — 601022-10 Warning Danger...
  • Page 230 Thoroughly clean the oil drain plug with magnet. -— ring Mount the oil drain plug with the magnet and seal — tighten Guideline Oil drain plug (14.8 with M12x1.5 20 Nm magnet Warning Danger scalding Engine motorcycle is ridden. and gear oil very hot when the Wearsuitable protective clothing...
  • Page 231 Insert oil filters — O-rings Oil the of theoil filter Mountoil filter covers. cov- -— © tighten Mount screws. — Guideline (4.4 Screw, filter 6 Nm cover & PH Warning scalding Engine Danger motorcycle and gear oil very hot when the is ridden.
  • Page 232 O-rings. Position oil with the screen — tighten plug O-ring. Mountand with the screw — Guideline Plug, (11.1 M20x1.5 15 Nm screen _802215-10 O-rings. Position oil with the screen — O-ring. tighten plug with the Mount and screw — Guideline Plug, M20x1.5 15 Nm...
  • Page 233 Info engine poor-quality engine engine. Too little oil results in premature of the wear —_| Main work plug O-ring Removefiller and the from the clutch cover, — engine fill up with oil. Engine (SAE 10W/60) (00062010035) (—" 278) Engine (SAE 1OW/50) (4 279) Info In order...
  • Page 234 Condition stator is disconnected. winding Stator check the resistance. measurement specified points. Measure the resistance between the —, Stator, connector EN Stator, connector EN — Alternator winding Stator resistance 0.15 ...0.309 (68 °F) 20 °C correspond setpoint If the indicated value does not »...
  • Page 235 IGNITION SYSTEM 22 — 600894-10 G00723-10 winding ground (terminal 31). Stator check short circuit specified points. Measure the resistance between the Stator, Measuring point (—) connector EN Ground — Resistance «QQ correspond setpoint If the indicated value does not to the value: »...
  • Page 236 Info The results of the measurements the individual coils deviate noticeably from each other. must not generator Alternating voltage 50 V stator winding at 4000 rpm: (68 °F) 20 °C correspond setpoint If the indicated value does not to the »...
  • Page 237 Ignition coil primary Resistance of 1.105 1.4950 winding 20 °C °F) displayed correspond specifica- If the value does » tions: Change ignition coil. —...
  • Page 238 Condition diagnostics tool is connected and running. “Engine adaptation Execute electronics” "Functions" “Delete > > — values". adaptation & values deleted. Program position the gear (— 217) sensor. — ignition. Switch off diagnostics Disconnect the tool. — 401897-01 engine activating grip.
  • Page 239 Design l-cylinder engine, 4-stroke water-cooled Displacement 690 cm? (42.11 Stroke 84.5 (3.327 in) (4.02 in) Bore Compression 12.6:1 ratio Control OHC, valves controlled via rocker arm, chain drive Valve diameter, intake (1.57 in) diameter, Valve exhaust (1.34in) Valve play, cold 0.07 0.13 (0.0028...
  • Page 240 bearing pin Camshafts diameter, Next exhaust 39.95 1.5728 Next inlet 17.96 0.7071 spring Valve spring cap) Minimum length (without 42.3 (1.665 in) valve Valve spring thickness 2.4... 2.5 (0.094 0.098 Valve valve diameter stem Exhaust 5.93 0.2335 Intake 5.93 0.2335 guide Valve diameter...
  • Page 241 facing Clutch basket contact surface of clutch discs 0.02 regulator spring length Oil pressure minimum (0.9984 in) valve 25.36 Oil pump engine Clearance between external 0.20 0.0079 rotor <= case Clearance between external rotor and internal 0.20 0.0079 rotor <= (0.0016 Axial clearance 0.04...
  • Page 242 Screw, autodecompression (2.2 3...4Nm 3 Ibf Loctite®243TM Screw, axial lock of camshaft 10 Nm (7.4 Loctite®243TM Screw, (7.4 clutch 10 Nm cover cylinder Screw, clutch slave M6x20 10 Nm (7.4 Loctite®243TM Screw, cylinder clutch slave M6x35 10 Nm (7.4 Loctite®243TM cylinder 10 Nm (7.4...
  • Page 243 Cylinder Tightening head sequence: screw Tighten diagonally,beginning with timing chain rear screw on shaft. Step 15 Nm (11.1 Step 30 Nm (22.1 Step (33.2 45 Nm Step 60 Nm (44.3 engine Lubricated with Oil line for oil pressure M10x1 10 Nm (7.4 sensor (7.4...
  • Page 244 Engine 24.4.1 qt.) Engine 1.70 | (1.8 Engine (SAE 10W/60) (00062010035) ("= 278) Engine Engine (SAE 10W/50) engine Alternative 279) (<8 24.4.2 Coolant Coolant 1.20 1 (1.27 qt.) Coolant (©" 278) 24.4.3 Fuel capacity, gal) Super Total fuel tank (3.2 unleaded (ROZ 95/RON...
  • Page 245 (690 Enduro R 90/90 21 M/C 54R TT 140/80 18 M/C 70R TT Pirelli MT 21 RALLYCROSS Pirelli MT 21 RALLYCROSS The tires specified represent possible production Additional information available in of the series tires. the Service section under: http://www.ktm.com...
  • Page 246 Fork number 14.18.8N.10 part Systems Fork WP Performance 4860 MXTA SPLIT Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks payload Full 10 clicks damping Rebound Comfort 20 clicks Standard 15 clicks Sport 10 clicks payload Full 10 clicks Spring length preload spacer(s) (18.31 in)
  • Page 247 (145 psi) Gas pressure 10 bar (0.71 in) Static Riding 70... 80 (2.76 3.15 length Fitted (15.55 in) Shock absorberfluid Shock absorber fluid (SAE 2.5) («= (5018075181) 279) Screw, chain guard EJOT 2 Nm (1.5 Screw, combination instrument EJOT 1 Nm (0.7 Screw, plate...
  • Page 248 Screw, (3.7 brake fluid reservoir of 5 Nm rear brake Screw, chain guard 2 Nm (1.5 Loctite®243TM Screw, guide (5.9 chain 8 Nm Screw, sliding (5.9 chain guard 8 Nm Loctite®243TM Screw, fan hood 4 Nm Screw, front brake disc 14 Nm (10.3 Loctite®243TM...
  • Page 249 Screw, clamp (8.9 main silencer 12 Nm Copper paste Screw, main silencer holder 25 Nm (18.4 Screw, (18.4 main silencer holder 25 Nm fuel tank Screw, (18.4 footrest bracket M8x16 25 Nm rear Screw, side stand bracket 25 Nm (18.4 Loctite®243TM Screw, spring side stand...
  • Page 250 Note damage Components damaged destroyed incorrectly. Material become pressure cleaneris used high bearings, forces into the electrical components, throttle cables, water connectors, etc. pressure high destroys Pressure which is malfunctions and components. causes jet directly bearings. direct the electrical components, throttle cables water connectors,...
  • Page 251 protection Push backthe of the handlebar controls covers — penetrated evaporate. allow any water that has motorcycle moving After the has cooled off, lubricate all parts — bearings. Clean the chain. (“= — (except Treat bare metal for brake discs and exhaust parts sys- —...
  • Page 252 Clean the chain. (— —...
  • Page 253 Store the vehicle in location that is not — temperature. fluctuations in Info jacking motorcycle. KTM recommends up the motorcycle (-" Raise the with lift stand. — motorcycle Cover the with tarp similar...
  • Page 254 Removethe motorcycle from the lift stand. Recharge battery. battery. Install the (<> 100) Set the clock. (©" 125) maintenance preparing Perform checks and when measures use. Take test ride. 401059-01...
  • Page 255 The most up-to-date scopes may course always happy service schedule be found KTM Dealer.net. Your authorizedKTM dealer will be advise you, sporting after every Every two years Every year 20,000 every (12,400 10,000 (6,200 mi)
  • Page 256 Read the KTM test ride. adjustmentusing diagnostics Check the CO the KTM tool. Maketheservice entry in KTM Dealer.net and in the Service and Manufacturer War- ranty Booklet. One-time interval © Periodic interval sporting after every Every year (6,200...
  • Page 258 - M 1 0 6 9 0 E n d u r o x 3 0 2 GI F 2 0 1 7 - 2 0 1 8 - x 3 0 1 ( 2 . 4 6 “ A t t G2 0 L _ ] &...
  • Page 259 Components: Engine electronics control unit Fuse Battery Alternator Starter relay with main fuse auxiliary relay Start Electric starter system Voltage regulator ground assigned) X291 Connector for accessory (terminal 31) ACC 1 (not plus (terminal 30) (not assigned) X292 Connector for accessory ACC 1...
  • Page 260 ¥ 8 9 " ar t ! 9 8 h ) a ' g — < a P p e a — < 9 p h y M ” E C ' L ! p e y w bled —I wove ‘...
  • Page 261 Components: Engine electronics control unit Fuse Fuse Light relay Power relay Fuel pump Combination instrument Ignition steering lock Emergency switch, electric starter button Diagnostics X295 connector...
  • Page 262 f 2 . F 8 ( 2 . 6 8 o — 7 d b o . “ F S! ~ | F s l 2 - X 1 2 2 - X 1 2 2 Fui 2 & - X 1 2 6 - X 1 2 6 Fu l 2 Ful a...
  • Page 263 Components: high beam, beam Fuse Fuse Combination instrument Horn Parking light Light switch, high signal switch horn button, beam flasher button, turn...
  • Page 264 B E S ( 3 . F B ( 3 . F B ~ > — — a b e r , y e - b e , y e b u , © yet u 6 9 0 - B 7 6 E n d u r o ~ | A H I 2 >...
  • Page 265 Components: light Front brake switch light Rear brake switch plate lamp License light Brake/tail...
  • Page 266 4. 8 6 9 0 - K 2 0 E n d u r o - X 2 9 - X 2 9 E/ 2 ( 8 . 4 6 3 . A 3 P1 0 1 3 . 0 3 - $ 2 4 2 0 1 7 - 2 0 1 8 "|...
  • Page 267 Components: signal relay Turn Combination instrument signal, Turn front left signal, right Turn front Turn signal, left rear signal, right Turn rear Light switch, high signal horn button, beam flasher button, turn switch...
  • Page 268 B8 3 6- 8 . > — o — ‘ - X 1 2 9 - X 1 2 9 & Fu l 2 Ful 2 6 9 0 X 2 9 4 E n d u r o - | c R M - X 2 9 3 2 0 1 7 - 2 0 1 8 ~ F u i 2...
  • Page 269 Components: temperature switch Radiator fan Fuse Fuse Radiator fan X293 Connector for accessory ground (terminal 31) ACC 2 (not assigned) plus (terminal 15) assigned) X294 Connector for accessory ACC 2 (not...
  • Page 270 f o — t e ~ | F s l 2 ~Al l + X 1 2 7 - X 1 2 7 Fu l 2 G F / 4 8 - M 6 0 B R E E E E L 6 9 0 1 1 7 / 1 7 7 E R E E E...
  • Page 271 Components: Engine electronics control unit grip Throttle Fuse Evaporate (optional) emission control valve Injection valve cylinder stepper Throttle motor Ignition 1, (cylinder R51/1 coil Ignition (cylinder R51/2 coil...
  • Page 272 ¢ i e r ( 9 . A 1 ( T A N “ A N - B 5 1 ~ _ D Y i 4 G r a C U l 4 § X4 5 C U I 4 —D Y I 4 .
  • Page 273 Components: Engine electronics control unit temperature Intake air sensor (cylinder Coolant temperature sensor pressure sensor Clutch switch Lambda (cylinder sensor Combination instrument Switch Map-Select switch...
  • Page 274 —_ \ — _ M O . A 2 “ A t t # G F i 4 8 2 G F i 4 8 )-xt - B 3 0 6 9 0 G F I 4 8 A M I 3 “...
  • Page 275 Components: Engine electronics control unit Ambient air pressure sensor Rollover sensor Side stand sensor Gear position sensor cylinder Induction manifold pressure sensor Combination instrument...
  • Page 276 M 1 . A 1 9. 1 “ A N > G F / 4 8 6 9 0 E n d u r o - B 3 7 @ G F i 4 8 a u i 2 A T I 2 - X 5 2 2 0 1 7 - 2 0 1 8 G F I 4 8...
  • Page 277 Components: Engine electronics control unit Fuel level sensor position Crankshaft sensor Combination instrument...
  • Page 278 n a o | _ | ‘ J E . E B F 3 8 3 6 . 6 8 o — m n — c o — m b e p u , o r p u , M 0 A 2 - A N 1 - F 9 b e p u ,...
  • Page 279 Components: Engine electronics control unit ABS control unit speed Front wheel sensor speed Rear wheel sensor Fuse ABS fuse ABS fuse Combination instrument Diagnostics X295 connector Cable colors: Black Brown Blue Green Gray Light blue Orange Pink Violet White Yellow...
  • Page 280 Recommended Motorex® COOLANT M3.0 — Standard/classification p. 301) JASO T903 MA 301) (SAE 10W/60) — KTM LC4 2007+ — Guideline specified specifications only engine comply (see container) oils that with the standards and that —...
  • Page 281 Standard/classification JASOT903 MA 301) (© p. 301) (SAE 10W/50) — Guideline only engine comply specified specifications oils that with the standards (see container) and that -— corresponding properties. possess Fully synthetic engine supplier Recommended Motorex® Synt Power — Standard/classification 301) (SAE 4) —...
  • Page 282 supplier Recommended Motorex® Chain Clean supplier Recommended Motorex® Fuel Stabilizer supplier Recommended Motorex® Bike Grease 2000 supplier Recommended Systems WPPerformance Racing Grease IPR 2 supplier Recommended Bel-Ray® MC-11® supplier Recommended Lubcon® Turmogrease® PP 300 supplier Recommended Molykote® 33 Medium supplier Recommended Motorex®...
  • Page 283 supplier Recommended Motorex® Moto Polish & Shine — supplier Recommended Motorex® Moto Protect — supplier Recommended Motorex® Quick Cleaner — supplier Recommended Motorex® Synthetic Joker 440 —...
  • Page 284 Art. 00029013004 no.: 00029013004 HOO503-01 00029013015 Art. no.: 00029013015 HOO514-01 Art. 00029013100 no.: 00029013100 HOO518-01 Art. 00029095050 no.: Feature safety plug Nominal voltage 230 V Mains fuse length Powercable (16 ft) approx. Charger length (16 ft) cable HO1065-01 approx.
  • Page 285 Art. 00029095051 no.: Feature plug voltage Nominal Mains fuse length (16 ft) Powercable approx. Charger length (16 ft) cable HO1065-01 approx. 00029095052 Art. no.: Feature safety plug Nominal voltage 230 V Mains fuse length (16 ft) Powercable approx. Charger length cable (16 ft) HO1065-01...
  • Page 286 Art. 15112018100 no.: Feature (0.71 ... 0.91 15112018100 HO00522-01 50329050000 Art. no.: 50329050000 HOO565-01 Art. 51012011000 no.: 51012011000 HO0572-01 Art. 58429009000 no.: 58429009000 H00593-01...
  • Page 287 Art. 58429037043 no.: Feature Inside diameter 43.9 (1.728 in) 58429037043 HOO598-01 58529005000 Art. no.: 58529005000 HOO608-01 Art. 59029019000 no.: 59029019000 HO0610-01 Art. 59029026006 no.: Feature Diameter (0.2382in) 6.05 59029026006 HO0612-01...
  • Page 288 Art. 59029033000 no.: 59029033000 H00613-01 59029041100 Art. no.: Feature piece (0.0039 0.10... 0.25 0.0098 59029041100 HO0616-01 Art. 60029057000 no.: 60029057000 HO0650-01 Art. 60029057100 no.: 60029057100 H00651-01...
  • Page 289 Art. 61029093000 no.: 61029093000 HOO659-01 61029094000 Art. no.: «Ad 61029094000 HOO660-01 Art. 61229001000 no.: 61229001000 HO0662-01 Art. 62529055100 no.: 62529055100 HG0693-01...
  • Page 290 Art. 75012001060 no.: 75012001060 H00703-01 75012001070 Art. no.: 75012001070 HOO704-01 Art. 75029005000 no.: 75029005000 HOO705-01 Art. 75029015102 no.: Feature Height (1.77 in) (4.02 in) Diameter 75029015102 HO00706-01...
  • Page 291 Art. 75029021000 no.: 75029021000 H00707-01 75029033000 Art. no.: «AX 75029033000 HO0708-01 Art. 75029035000 no.: 75029035000 H00710-01 Art. 75029036000 no.: 75029036000 HOO711-01...
  • Page 292 Art. 75029044010 no.: 75029044010 HOO0712-01 75029044020 Art. no.: 75029044020 HOO7 13-01 Art. 75029047000 no.: 75029047000 H00714-01 Art. 75029047050 no.: 75029047050 H00715-01...
  • Page 293 Art. 75029047051 no.: 75029047051 HO0716-01 75029048100 Art. no.: 75029048100 HO0718-01 Art. 75029050000 no.: 75029050000 H00719-01 Art. 75029051000 no.: 75029051000 HOO0721-01...
  • Page 294 Art. 75029055000 no.: 75029055000 HOO722-01 75029080000 Art. no.: 75029080000 HOO723-01 Art. 75029080050 no.: 75029080050 HO0724-01 Art. 75029081000 no.: 75029081000 HOO725-01...
  • Page 295 Art. 75029090000 no.: 75029090000 HO0726-01 75029091000 Art. no.: 75029091000 HOO727-01 Art. 75029172000 no.: Feature Drive 1/2 in Hexagonalpart (0.55in) Length (3.35 in) 75029172000 HO0729-01 Art. 77329006000 no.: 77329006000 HOO764-01...
  • Page 296 Art. 77329010000 no.: 77329010000 HOO765-01 77329051000 Art. no.: 77329051000 HOO771-01 Art. 78029060000 no.: 78029060000 HOO795-01 Art. 000291 96000DE no.: 00029196000DE HO1112-01...
  • Page 297 Art. 00029196000EN no.: 00029196000EN HO1113-01 O0029196000ES Art. no.: 00029196000ES HO1117-01 Art. 00029196000FR no.: 00029196000FR HO1116-01 Art. 000291 96000IT no.: 000291 96000IT HO1115-01...
  • Page 298 Art. O0029196000JP no.: 00029196000JP HO1118-01 O00029196000US Art. no.: 00029196000US HO1114-01 Art. T103 no.: Feature adjustable (0.16 in) Diameter T103 H00838-01 Art. TLO6S no.: Feature Diameter (2.68 2.95 H00841-01...
  • Page 299 Art. T107S no.: T107S HO0842-01 Art. T1120 no.: Feature (0.31 in) Diameter T120 HOO844-01 Art. T1206 no.: ») Feature Diameter 15... 30 (0.59 ... 1.18 71206 HOO0880-01 Art. T1207S no.: 712078 HO00881-01...
  • Page 300 Art. T1240S no.: T1240S HOO890-01 Art. T129 no.: Feature (0.59 Diameter 1.18 T129 HOO846-01 Art. T1401 no.: cS» Feature (1.89 in) Diameter T1401 HO0894-01 Art. T14026S1 no.: Feature Diameter (0.67in) T14026S1 HO0916-01...
  • Page 301 Art. T14032 no.: Feature opening (0.87in) T14032 HOO920-01 T1403S Art. no.: Feature (1.89 in) Diameter (2.36 in) Diameter T1403S HOO896-01 Art. T14040S no.; Feature (1.89 in) Diameter T14040S HOO922-01 Art. T1515 no.: —_ Feature Diameter (0.71 in) T1515 HOO900-01...
  • Page 302 Art. T170S1 no.: 1717081 HOO0855-01...
  • Page 303 development required separate specification motorcycles Different technical directions the JASO T903 MA — standard. Earlier, engine industry motorcycles oils from the automobile used for becausethere separate motor- was no were specification. cycle long engines, motorcycle engines high Whereas service intervals demanded for automobile the focus for performance...
  • Page 304 Safety system prevents locking of the wheels that driving straight when ahead without the influenceof lateral forces adjuster spring adjust- Preload Device elements which enables of the spring preload ment...
  • Page 305 Art. Article number circa compare example e.g. etc. et cetera inter alia number possibly poss.
  • Page 306 Brake discs checking: &% & KERR & ABS) Brakefluid RESTORE Accessories changing front brake, 0... 20....004. brake, changing Airfilter rear ....InstalliNg adding: brake; rear wane « SOMME Topping FOMOVINE up brake fluid of front brake & ..Air filter fluid Brake level...
  • Page 307 installing Cylinder Nikasil® coating freewheel, ......... freewheel, removing ...000005 main shaft, disassembling Diagnostics connector ..... piston, checking/measuring .... Disassembling engine piston/cylindermounting clearance, determin- removing alternator cover, ..... Woahalameralenlans removing camshafts, installing rocker arm, ....0.0005 ....e00. removing clutch cover, removing rocker arm, ..-.-..-...
  • Page 308 FEMOVINE: Oil, DUMPS, Fuel pump soennanaswe drive, removing changing starter ...00008 & &i &i REARS Engine electronics unit control Fuel screen TeSCHLING: GHanging: & scaEEERESI Engine guard Fuse HISTANNS individual power changing consumers, eecteeoner ..fEMOVINE « cease Engine number position Gear ..
  • Page 309 Spring, TEMOVINE.< Oil filter some Changing: static-sag, checking: seseiecs wcvisiee installips article Shock absorber number SaaSsG ....FOEMOVINGE: Side Sede cover screens WIGUNENE systems GI6ANINE 227,229 fEMGVING sseeeweas scien Operating substances Spare parts ....-..- 2.0.0... Spoke tension QNeCKINE: Parkinglight bulb TREO Starting Changing:...
  • Page 310 Page:09 of Tl: cemeEReeee é Page 1Oof Tle & erie ae¢ Page: LT Of TL. £4 SESS & Worries: scomannaricawanaaim...
  • Page 311 READY TO RACE www.ktm.com > 3206323en 09/2017 &> Sportmotorcycle GmbH sphce 5230 Mattighofen/Austria Photo: Mitterbauer/KTM g c d hittp://www.ktm.com ‘...

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