Page 1 OWNER'S MANUAL 2017 690 SMC R Art. no. 3213548en...
Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.
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 assurance processes that lead to the maximum possible quality of the products.
Page 5: Table Of Contents
TABLE OF CONTENTS Fork part number ..........22 TABLE OF CONTENTS MEANS OF REPRESENTATION ........7 Shock absorber article number ......22 Symbols used ............7 CONTROLS..............23 Formats used............8 Clutch lever............23 SAFETY ADVICE.............. 9 Hand brake lever..........23 Use definition - intended use ........
Page 6 TABLE OF CONTENTS 6.12 Closing filler cap..........38 10.4 Compression damping of the shock absorber..65 6.13 Seat unlocking........... 38 10.5 Adjusting the low-speed compression damping of the shock absorber ..........65 6.14 Handrails ............39 10.6 Adjusting the high-speed compression damping 6.15 Passenger footrest..........
Page 7 TABLE OF CONTENTS 11.18 Checking the chain, rear sprocket, engine 14 ELECTRICAL SYSTEM ..........116 sprocket, and chain guide ........83 14.1 Removing the battery ........116 11.19 Adjusting the basic position of the clutch lever ..87 14.2 Installing the battery ........
Page 8 TABLE OF CONTENTS 17.2 Changing the engine oil and filter, cleaning the 22.9 Chassis tightening torques ........ 183 oil screens ........... 150 23 SUBSTANCES ............188 17.3 Draining the engine oil ........150 24 AUXILIARY SUBSTANCES ........... 191 17.4 Removing the oil filter ........
Page 9: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required.
Page 10: Formats Used
MEANS OF REPRESENTATION Formats used The typographical formats used in this document are explained below. Specific name Identifies a proprietary name. Name ® Identifies a protected name. Brand™ Identifies a brand available on the open market. Underlined terms Refer to technical details of the vehicle or indicate technical terms that are explained in the glossary.
Page 11: Safety Advice
SAFETY ADVICE Use definition - intended use KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race courses or offroad. Info The motorcycle is only authorized for operation on public roads in the homologated version.
Page 12: Degrees Of Risk And Symbols
SAFETY ADVICE Degrees of risk and symbols Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.
Page 13: Safe Operation
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. 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 14: Protective Clothing
– Always wear protective clothing that is in good condition and meets the legal regulations. 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 contained in the vehicle but can be ordered under the number in parenthe- ses.
Page 15: Owner's Manual
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.
Page 16: Important Notes
Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the warranty.
Page 17: 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. A list of authorized KTM dealers can be found on the KTM website.
Page 18: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left side (example) E00520-10...
Page 19 VIEW OF VEHICLE Hand brake lever ( p. 23) Clutch lever ( p. 23) Handrails ( p. 39) Filler cap Engine number ( p. 21) Shift lever ( p. 40) Side stand ( p. 41) Seat unlocking ( p. 38) Compression damping of the shock absorber ( p.
Page 20: View Of Vehicle, Rear Right Side (Example)
VIEW OF VEHICLE View of vehicle, rear right side (example) E00521-10...
Page 21 VIEW OF VEHICLE Ignition/steering lock ( p. 27) Fork compression adjustment Light switch ( p. 25) Turn signal switch ( p. 25) Horn button ( p. 24) Function buttons ( p. 28) Indicator lamps ( p. 29) Emergency OFF switch ( p.
Page 22: Serial Numbers
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 23: Key Number
SERIAL NUMBERS Key number  can be found on the KEYCODECARD. The key number 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. 401949-10...
Page 24: Fork Part Number
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 25: Controls
CONTROLS 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 handlebar. The hand brake lever operates the front brake.
Page 26: Throttle Grip
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 –...
Page 27: Light Switch
CONTROLS 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 on. High beam on – Light switch is turned upward. In this position, the high beam and tail light are switched on.
Page 28: Emergency Off Switch
CONTROLS 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 ignition circuit is inter- rupted, a running engine stops, and the engine cannot be started. Emergency OFF switch on –...
Page 29: Ignition/Steering Lock
CONTROLS Ignition/steering lock  The ignition/steering lock is located in front of the seat. Possible states Ignition OFF – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. The ignition key can be removed.
Page 30: Function Buttons
CONTROLS 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 mas- ter 2 (TRIP 2).  Press the SET button to reset the trip master 1 function (TRIP 1) and trip master 2 func- tion (TRIP 2) to 0.0.
Page 31: Indicator Lamps
CONTROLS 6.10.4 Indicator lamps The indicator lamps offer additional information about the operating state of the motorcy- cle. Possible states The turn signal indicator lamp flashes green simultaneously with the turn signal – The turn signal is switched on. The idling speed indicator lamp lights up green – The transmission is shifted to idle.
Page 32: Display
CONTROLS 6.10.5 Display When the ignition is switched on, all display segments light up for one second as a function check. 400836-01 LEnGth After the display function check, the wheel circumference LEnGth is displayed for one sec- ond. Info The number 1870 mm equals the circumference of the 17" front wheel with a series production tire.
Page 33: Speed Display
CONTROLS 6.10.6 Speed display  The speed is shown in kilometers per hour km/h or in miles per hour mph. 401443-10 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.
Page 34: Time
CONTROLS – Switch on the ignition by turning the ignition key to position ON – Press the MODE button repeatedly until the ODO display mode is active. – Keep the MODE button pressed until the display mode changes from km/h to mph or from mph to km/h.
Page 35: 6.10.10 Odo Display
CONTROLS – Switch on the ignition by turning the ignition key to position ON – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button and the SET button pressed simultaneously. The time display begins to flash. –...
Page 36: Setting/Resetting Display Trip 2
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 37: 6.10.13 Trip F Display
CONTROLS 6.10.13 TRIP F display If the fuel level drops to the reserve mark, the display automatically changes to TRIP F and starts to count from 0.0, regardless of the previous display mode. Info The low fuel warning lamp lights up in parallel to the TRIP F display. 401447-01 6.10.14 GEAr display In display mode GEAr, the gear currently engaged is displayed.
Page 38: 6.10.15 Coolant Temperature Indicator
CONTROLS 6.10.15 Coolant temperature indicator The temperature display 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 temper- ature warning lamp lights up. Possible states Engine cold –...
Page 39 CONTROLS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. –...
Page 40: Closing Filler Cap
CONTROLS 6.12 Closing filler cap – Put the filler cap back on and turn the ignition key 90° clockwise. – Remove the ignition key and fold down the cover. 101976-01 6.13 Seat unlocking  The loop unlocks the seat. 101977-10...
Page 41: Handrails
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. 101978-10 6.15 Passenger footrest The passenger footrests are foldable. Possible states Passenger footrest folded in – For operation without a passenger. •...
Page 42: Shift Lever
CONTROLS 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 43: Foot Brake Lever
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 44: 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 characteristic. – Only use tires/wheels approved by KTM with the corresponding speed index. Warning Danger of accidents Reduced road grip with new tires. –...
Page 45: Running In The Engine
When using your vehicle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.
Page 46: Loading The Vehicle
PREPARING FOR USE Guideline Maximum engine speed During the first: 1,000 km (620 mi) 6,000 rpm After the first: 1,000 km (620 mi) 7,800 rpm – Avoid fully opening the throttle! Loading the vehicle Warning Danger of accidents Unstable handling characteristics. –...
Page 47 PREPARING FOR USE Warning Danger of accidents Poor visibility for other road users due to slipped baggage. – If the tail light is covered, you are less visible to traffic behind you, especially when it is dark. Check that your baggage is fixed properly at regular intervals.
Page 48: Riding Instructions
RIDING INSTRUCTIONS Performing checks and vehicle care when preparing for use Info Before each use, check the state and roadworthiness of the vehicle. Make sure that the vehicle is in perfect technical condition before use. – Check the engine oil level. ( p.
Page 49: Starting
RIDING INSTRUCTIONS Starting 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 If the vehicle is operated with a discharged battery or without a battery, electronic components and safety equipment may be damaged.
Page 50 Take the weight off the side stand and swing it back up with your foot as far as it will Switching off ABS KTM recommends riding with ABS at all times. However, situations may arise in which ABS is not advantageous.
Page 51: Starting Off
RIDING INSTRUCTIONS Starting off – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully. Shifting, riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control. –...
Page 52 RIDING INSTRUCTIONS Warning Danger of accidents Reduced road grip with cold tires. – On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured. Warning Danger of accidents Reduced road grip with new tires. –...
Page 53 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 properly, and contact an autho- rized KTM workshop. – Shift into a higher gear when conditions allow (incline, road situation, etc.).
Page 54: Applying The Brakes
Warning Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)
Page 55 RIDING INSTRUCTIONS Warning Danger of accidents The brake system fails in the event of overheating. If the foot brake lever is not released, the brake linings drag continuously. – Take your foot off the foot brake lever when you are not braking. Warning Danger of accidents Longer stopping distance due to higher overall weight.
Page 56: Stopping, Parking
RIDING INSTRUCTIONS Info When the ABS is enabled, you can achieve maximum braking power even on low grip surfaces such as sandy, wet, or slippery terrain without locking of the wheels. Warning Danger of accidents Banked or laterally sloping ground reduces the maximum possible delay. –...
Page 57: Transport
RIDING INSTRUCTIONS – Park the vehicle on a firm and level surface. – Ensure that nobody sits on the vehicle when the vehicle is parked on a stand. Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. –...
Page 58: Refueling
RIDING INSTRUCTIONS 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. – Switch off the engine and remove the ignition key.
Page 59 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 60 RIDING INSTRUCTIONS – Switch off the engine. – Open the filler cap. ( p. 36) –  Fill the fuel tank with fuel up to measurement Guideline 20 mm (0.79 in) Measurement  Total fuel tank 12 l (3.2 US gal) Super unleaded (ROZ 95/RON 95/PON capacity, approx.
Page 61: Service Schedule
10,000 km (6,200 mi) / after every sporting use after 1,000 km (620 mi) ○ ● ● ● ● Read out the fault memory using the KTM diagnostics tool. ○ ● ● ● ● Check that the electrical system is functioning properly.
Page 62 SERVICE SCHEDULE Every two years Every year every 20,000 km (12,400 mi) every 10,000 km (6,200 mi) / after every sporting use after 1,000 km (620 mi) ○ ● ● ● ● Check the shock absorber and fork for leaks. Perform a fork service and shock absorber service as needed and depending on how the vehicle is used.
Page 63 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 64: Recommended Work
SERVICE SCHEDULE Recommended work Every four years Every year every 30,000 km (18,600 mi) every 10,000 km (6,200 mi) / after every sporting use after 1,000 km (620 mi) ● Check the frame. ● Check the swingarm. ● ● Check the swingarm bearing for play. ○...
Page 65: Tuning The Chassis
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 66: Adjusting The Rebound Damping Of The Fork
TUNING THE CHASSIS Guideline Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 10.3 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. –...
Page 67: Compression Damping Of The Shock Absorber
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled 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 68: Adjusting The High-Speed Compression Damping Of The Shock Absorber
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled 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 69: Adjusting The Rebound Damping Of The Shock Absorber
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled 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 70: Handlebar Position
TUNING THE CHASSIS – 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 Sport 10 clicks 601891-10 Full payload 10 clicks...
Page 71: Adjusting The Handlebar Position
TUNING THE CHASSIS 10.9 Adjusting the 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 kink the cables and lines. –...
Page 72: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 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. – Raise the motorcycle in the area of the footrest bracket. Neither wheel is in contact with the ground.
Page 73: Raising The Motorcycle With The Rear Wheel Stand
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 Raising the motorcycle with the rear wheel stand Note Danger of damage The parked vehicle can roll away or fall over. –...
Page 74: Removing The Rear Of The Motorcycle From The Wheel Stand
SERVICE WORK ON THE CHASSIS 11.4 Removing the rear of the motorcycle from the wheel stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Secure the motorcycle against falling over. –...
Page 75: Taking The Motorcycle From The Front Lifting Gear
SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Align the front wheel stand with the fork legs using the adapters. Front wheel stand (61029055300) Info Always raise the rear of the motorcycle first. –...
Page 76: Cleaning The Dust Boots Of The Fork Legs
SERVICE WORK ON THE CHASSIS 11.7 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 70) – Remove the fork protector. ( p. 75) Main work –  Push dust boots of both fork legs downward.
Page 77: Removing The Fork Protector
SERVICE WORK ON THE CHASSIS 11.8 Removing the fork protector –  Remove screws and take off clamp. –  Remove screws on left fork leg. Remove the fork protector. – Remove the screws on the right fork leg. Remove the fork protector. 101986-10 11.9 Installing the fork protector...
Page 78: Removing The Seat
SERVICE WORK ON THE CHASSIS 11.10 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. 101977-10 11.11 Mounting the seat 101988-10 –...
Page 79: Removing The Air Filter
SERVICE WORK ON THE CHASSIS 11.12 Removing the air filter Preparatory work – Remove the seat. ( p. 76) Main work –  Remove screws –  Remove the upper part of the air filter box 601882-10 Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine.
Page 80: Installing The Air Filter
SERVICE WORK ON THE CHASSIS 11.13 Installing the air filter Main work – Clean the air filter box. –  Mount air filter Info The air filter must lie flush against the air filter box along the entire sealing sur- face ...
Page 81: Checking The Chain For Dirt
SERVICE WORK ON THE CHASSIS 11.14 Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 79) 400678-01 11.15 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. –...
Page 82: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS Info The service life of the chain depends largely on its maintenance. Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 71) Main work – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. –...
Page 83 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 sliding guard and determine  the chain tension Info  The upper chain section must be taut.
Page 84: Adjusting The Chain Tension
SERVICE WORK ON THE CHASSIS 11.17 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.
Page 85: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide
SERVICE WORK ON THE CHASSIS Main work –  Loosen nut – Loosen nuts  –  Adjust the chain tension by turning adjusting screws on 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 ...
Page 86 SERVICE WORK ON THE CHASSIS Main work – Shift the transmission to idle. – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket or engine sprocket is worn: – Change the power set. Info The engine sprocket, rear sprocket, and chain should always be replaced together.
Page 87 SERVICE WORK ON THE CHASSIS Info When the chain is replaced, the rear sprocket and engine sprocket should also be changed. New chains wear out faster on an old, worn rear sprocket or engine sprocket. – Check the chain sliding guard for wear. »...
Page 88 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 89: Adjusting The Basic Position Of The Clutch Lever
SERVICE WORK ON THE CHASSIS – Check that the chain guide is firmly seated. » If the chain guide is loose: – Tighten the screws on the chain guide. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 601884-01 Finishing work –...
Page 90: Checking/Correcting The Fluid Level Of The Hydraulic Clutch
SERVICE WORK ON THE CHASSIS – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw  – When adjusting the clutch lever, make sure to leave a minimum clearance to other parts of the vehicle. Guideline Minimum clearance 5 mm (0.2 in)
Page 91 SERVICE WORK ON THE CHASSIS 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.
Page 92: Brake System
– Only use spare parts on the brake system which have been approved and recom- mended by KTM. – Only use tires/wheels approved by KTM with the corresponding speed index. – Maintain the specified tire air pressure. – Service work and repairs must be performed professionally. (Your authorized KTM workshop will be glad to help.)
Page 93: Adjusting The Basic Position Of The Hand Brake Lever
BRAKE SYSTEM the brake pressure. The regulating process causes a slight pulsing of the hand and foot brake levers.  ABS warning lamp must light up after the ignition is switched on and go out after start- ing off. If it does not go out after starting off or if it lights up while riding, this indicates a fault in the ABS system.
Page 94: Checking The Brake Discs
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 thickness of the front and rear brake discs in several places to ensure that it ...
Page 95: Checking The Front Brake Fluid Level
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 Danger of accidents Old brake fluid reduces the braking effect.
Page 96: Adding Front 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 97: Checking The Front Brake Linings
Clean up overflowed or spilt brake fluid immediately with water. 12.6 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.)
Page 98: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM Warning Danger of accidents Damaged brake discs reduce the braking effect. If the brake linings are not changed in time, the brake lining carriers grind against the brake disc. As a consequence, the braking effect is greatly reduced and the brake discs are destroyed. –...
Page 99: Adjusting The Basic Position Of The Foot Brake Lever
BRAKE SYSTEM – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel  Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) Info You will know that contact has been made with the foot brake cylinder piston when there is increased resistance when you activate the foot brake lever.
Page 100: Checking Rear Brake Fluid Level
If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)
Page 101: Adding Rear Brake Fluid
If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)
Page 102 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 103: Checking The Rear Brake Linings
Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Damaged brake discs reduce the braking effect. If the brake linings are not changed in time, the brake lining carriers grind against the brake disc. As a consequence, the braking effect is greatly reduced and the brake discs are destroyed.
Page 104 BRAKE SYSTEM – Check the brake linings for minimum thickness  ≥ 1 mm (≥ 0.04 in)  Minimum thickness » If the minimum thickness is less than specified: – Change the rear brake linings. – Check the brake linings for damage and cracking. »...
Page 105: Wheels, Tires
WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 71) – Raise the motorcycle with the front wheel stand. ( p. 72) Main work –   Remove screw and pull wheel speed sensor out of the hole.
Page 106: Installing The Front Wheel
WHEELS, TIRES – Remove spacers  H00934-12 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. Main work –...
Page 107 WHEELS, TIRES – Lift the front wheel into the fork, position it, and insert the wheel spindle. –  Mount and tighten screw Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) –   Position the wheel speed sensor in the drill hole.
Page 108: Removing The Rear Wheel
WHEELS, TIRES – Take the motorcycle from the front lifting gear. ( p. 73) – Operate the front brake and compress the fork a few times firmly. The fork legs straighten. –  Tighten screws Guideline Screw, fork stub 15 Nm (11.1 lbf ft) 101999-10 Finishing work...
Page 109: Installing The Rear Wheel
WHEELS, TIRES – Pull out wheel spindle  to the point where the chain adjuster is no longer in contact with the adjusting screw. – Push the rear wheel forward as far as possible and take the chain off the rear sprocket. Info Cover the components to protect them against damage.
Page 110 WHEELS, TIRES Main work – Check the rear hub rubber dampers. p. 109) – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Replace the wheel bearing. – Remove spacer. – ...
Page 111: Checking The Rear Hub Rubber Dampers
WHEELS, TIRES – Push the rear wheel forward as far as possible and lay the chain on the rear sprocket. –    Mount wheel spindle and chain adjuster . Mount nut , but do not tighten it yet. –...
Page 112 WHEELS, TIRES Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 71) – Remove the rear wheel. p. 106) Main work –  Check bearing » If the bearing is damaged or worn: – Replace the bearings. –...
Page 113: Checking The Tire Condition
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 characteristic.
Page 114 DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manufacture. KTM recommends that the tires be changed after 5 years at the latest, regard- less of the actual state of wear.
Page 115: Tubeless Tire System
This results in better handling and riding comfort. The rigid rim design results in a spoke wheel that is almost entirely maintenance-free. KTM recommends that the tubeless sealing profile be changed after 5 years at the latest, regardless of the actual state of wear.
Page 116: 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 117 WHEELS, TIRES – 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 118: Electrical System
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 goggles. – Avoid contact with battery acid and battery gases. –...
Page 119 ELECTRICAL SYSTEM – Disconnect negative cable  from the battery. –  Take off positive terminal cover S00622-10 –   Disconnect ABS connection cable and positive cable from the battery. S00620-10 –  Remove screws –  Pull retaining bracket of the battery forward and remove it.
Page 120: Installing The Battery
ELECTRICAL SYSTEM 14.2 Installing the battery Main work – Insert the battery into the battery compartment with the terminals facing rearward. Battery (YTZ10S) ( p. 180) –   Position retaining bracket and mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) S00621-11 –...
Page 121 ELECTRICAL SYSTEM – Position positive terminal cover  –   Position washer and negative cable , and mount and tighten the screw. Guideline Screw, battery terminal 4.5 Nm (3.32 lbf ft) S00622-11 –  Position the engine electronics control unit –...
Page 122: Recharging The Battery
ELECTRICAL SYSTEM 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 goggles. – Avoid contact with battery acid and battery gases. –...
Page 123 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 124 ELECTRICAL SYSTEM Main work – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the bat- tery, and to test the alternator. With this device, you cannot overcharge the battery. Info ...
Page 125: Changing The Main Fuse
ELECTRICAL SYSTEM 14.4 Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is in the housing of the starter relay next to the battery. Preparatory work –...
Page 126: Changing The Abs Fuses
ELECTRICAL SYSTEM – 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. – Install a new main fuse. Fuse (58011109130) ( p.
Page 127 ELECTRICAL SYSTEM Info Two fuses for the ABS are located under the seat. These fuses protect the return pump and the hydraulic unit of the ABS. The third fuse, which protects the ABS control unit, is located in the fuse box. Preparatory work –...
Page 128: Changing The Fuses Of Individual Power Consumers
ELECTRICAL SYSTEM Finishing work – Position the EFI control unit. – Mount the battery cover. – Mount the seat. ( p. 76) 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 –...
Page 129 ELECTRICAL SYSTEM – Remove the defective fuse. Guideline Fuse 1 - 10 A - ignition, combination instrument, clock, engine electronics control unit Fuse 2 - 10 A - ignition, combination instrument, engine electronics control unit Fuse 3 - 10 A - fuel pump Fuse 4 - 10 A - radiator fan Fuse 5 - 10 A - horn, brake light, turn signal Fuse 6 - 15 A - high beam, low beam, parking light, tail light, license plate lamp...
Page 130: Removing The Headlight Mask With The Headlight
ELECTRICAL SYSTEM Replace the spare fuse in the fuse box so that it is available if needed. – Check that the power consumer is functioning properly. – Close the fuse box cover. Finishing work – Mount the seat. ( p. 76) 14.7 Removing the headlight mask with the headlight Preparatory work...
Page 131: Installing The Headlight Mask With The Headlight
ELECTRICAL SYSTEM – Disconnect plug-in connectors  for the turn signals and  for the headlight. – Remove the headlight mask. 102026-10 14.8 Installing the headlight mask with the headlight Main work –   Connect plug-in connectors of the headlight and of the turn signals.
Page 132 ELECTRICAL SYSTEM – Remove the cloth from the fender and position the headlight mask.  Holding lugs engage in the headlight mask. 102027-10 –   Position groove on counterpiece 102028-10 –   Position brake line guides . Mount and tighten screws Guideline Screw, headlight mask 5 Nm (3.7 lbf ft)
Page 133: Changing The Headlight Bulb
ELECTRICAL SYSTEM Finishing work – Check the headlight setting. ( p. 135) 14.9 Changing the headlight bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.
Page 134: Changing The Parking Light Bulb
ELECTRICAL SYSTEM – Detach spring bar  –  Remove headlight bulb – Insert a new headlight bulb into the headlight housing. Headlight (H4 / socket P43t) ( p. 181) – Fix the headlight bulb in the headlight using the spring bar. –...
Page 135 ELECTRICAL SYSTEM Main work –  Remove protection cap 600610-12 –  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.
Page 136: Changing The Turn Signal Bulb
ELECTRICAL SYSTEM 14.11 Changing the turn signal bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.
Page 137: Checking The Headlight Setting
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 138 ELECTRICAL SYSTEM 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 motor- cycle with rider (instructions on how to apply the mark: Checking the headlight set- ting).
Page 139: Cooling System
COOLING SYSTEM 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 regulated by a valve in the radia-  tor cap . The heat expansion causes the surplus coolant to flow into the compensating tank ...
Page 140: Checking The Antifreeze And Coolant Level
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 oper- ating temperature.
Page 141 COOLING SYSTEM – 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 specified value: –...
Page 142: Checking The Coolant Level
COOLING SYSTEM – Mount the radiator cap. 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 oper- ating temperature.
Page 143 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 figure. » If the coolant level does not match the specified value: –...
Page 144: Draining The Coolant
COOLING SYSTEM 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 oper- ating temperature.
Page 145: Filling/Bleeding The Cooling System
COOLING SYSTEM – 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 water pump M10x1...
Page 146 COOLING SYSTEM – Stand the motorcycle on its side stand on a horizontal surface. –  Remove radiator cap E00522-10 – Refill with coolant. Coolant ( p. 188) – Completely fill the radiator with coolant. – Mount radiator cap  E00523-10 –...
Page 147 COOLING SYSTEM 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.
Page 148: Tuning The Engine
TUNING THE ENGINE 16.1 Adjusting the engine characteristic Preparatory work – Switch off the ignition by turning the ignition key to position OFF – Remove the seat. ( p. 76) Main work –  Pull the Map‑Select switch and holder upward off of the retaining bracket.
Page 149: Checking The Basic Position Of The Shift Lever
TUNING THE ENGINE – Position the Map‑Select switch in the holder. – Slide the Map‑Select switch with the holder downward onto the retaining bracket. Finishing work – Mount the seat. ( p. 76) 16.2 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position.
Page 150: Adjusting The Basic Position Of The Shift Lever
TUNING THE ENGINE 16.3 Adjusting the basic position of the shift lever –   Remove screw with the washers and take off shift lever 401950-12 –  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.
Page 151: Service Work On The Engine
SERVICE WORK ON THE ENGINE 17.1 Checking the engine oil level Info The engine oil level must be checked when the engine is warm. Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work –...
Page 152: Changing The Engine Oil And Filter, Cleaning The Oil Screens
SERVICE WORK ON THE ENGINE 17.2 Changing the engine oil and filter, cleaning the oil screens – Drain the engine oil. p. 150) – Remove the oil filter. p. 151) – Clean the oil screens. p. 153) – Install the oil filter. p.
Page 153: Removing The Oil Filter
SERVICE WORK ON THE ENGINE – Place a suitable container under the engine. –  Remove oil drain plug with the magnet and seal ring. – Completely drain the engine oil. 100200-10 – Thoroughly clean the oil drain plug with magnet. –...
Page 154 SERVICE WORK ON THE ENGINE Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regula- tions. Preparatory work – Place a suitable container under the engine. Main work –...
Page 155: Cleaning The Oil Screens
SERVICE WORK ON THE ENGINE 17.5 Cleaning the oil screens Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden. – Wear suitable protective clothing and safety gloves. – In the event of scalding, rinse the area affected immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.
Page 156 SERVICE WORK ON THE ENGINE – Remove screw plug  with oil screen  and the O-rings. – Completely drain the engine oil. – Thoroughly clean the parts and sealing surface. 100206-10 –  Position oil screen with the O-rings. –...
Page 157: Installing The Oil Filter
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 covers – Mount and tighten the screws. Guideline Screw, oil filter cover 6 Nm (4.4 lbf ft) 102022-10 17.7...
Page 158: Adding Engine Oil
SERVICE WORK ON THE ENGINE 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.
Page 159 SERVICE WORK ON THE ENGINE 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.
Page 160: Cleaning, Care
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 161 CLEANING, CARE – 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 162: Checks And Maintenance Steps For Winter Operation
CLEANING, CARE – Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials. Preserving materials for paints, metal and rubber ( p. 192) – Treat all painted parts with a mild paint polish. Perfect Finish and high gloss polish for paints ( p.
Page 163 CLEANING, CARE – Clean the motorcycle. ( p. 158) – Clean the brake system. Info After EVERY trip on salted roads, thoroughly wash the brake calipers and brake linings with cold water and dry carefully. This should be done after the parts are cooled down and while they are installed.
Page 164: Storage
STORAGE 19.1 Storage Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. –...
Page 165 – Store the vehicle in a dry location that is not subject to large fluctuations in tempera- ture. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear wheel stand. ( p. 71) –...
Page 166: Preparing For Use After Storage
STORAGE Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust.
Page 167: Troubleshooting
Connect the plug-in connection of the fuel line. connection is not connected – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine has too little power. Air filter is very dirty Remove the air filter.
Page 168 Air in cooling system Fill/bleed the cooling system. p. 143) – FI warning lamp (MIL) lights/flashes Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine dies during the journey Lack of fuel Refuel. ( p.
Page 169 TROUBLESHOOTING Faults Possible cause Action – High oil consumption Engine oil too thin (low viscosity) Change the engine oil and filter, clean the oil screens. p. 150) – Headlight and parking light are not Fuse 6 blown Change the fuses of individual power consumers. functioning p.
Page 170: Blink Code
BLINK CODE Blink code FI of warning lamp (MIL) 02 FI warning lamp (MIL) flashes briefly 2x Error level condition Crankshaft position sensor - circuit fault Blink code FI of warning lamp (MIL) 09 FI warning lamp (MIL) flashes briefly 9x Error level condition Manifold absolute pressure sensor cylinder 1 - input signal too low Manifold absolute pressure sensor cylinder 1 - input signal too high...
Page 171 BLINK CODE Blink code FI of warning lamp (MIL) 15 FI warning lamp (MIL) flashes 1x long, 5x short Error level condition Rollover sensor - input signal too low Rollover sensor - input signal too high Blink code FI of warning lamp (MIL) 17 FI warning lamp (MIL) flashes 1x long, 7x short Error level condition...
Page 172 BLINK CODE Blink code FI of warning lamp (MIL) 27 FI warning lamp (MIL) flashes 2x long, 7x short Error level condition Accelerator position sensor circuit fault - accelerator position sensor voltage Blink code FI of warning lamp (MIL) 33 FI warning lamp (MIL) flashes 3x long, 3x short Error level condition Injector cylinder 1 - circuit fault Blink code FI of warning lamp...
Page 173 BLINK CODE Blink code FI of warning lamp (MIL) 45 FI warning lamp (MIL) flashes 4x long, 5x short Error level condition Lambda sensor heater cylinder 1, sensor 1 - short circuit to ground or open circuit Lambda sensor heater cylinder 1, sensor 1 - input signal too high Blink code FI of warning lamp (MIL) 65 FI warning lamp (MIL) flashes 6x long, 5x short...
Page 174 BLINK CODE Blink code FI of warning lamp (MIL) 85 FI warning lamp (MIL) flashes 8x long, 5x short Error level condition Accelerator position sensor circuit A - input signal too low Accelerator position sensor circuit A - input signal too high Blink code FI of warning lamp (MIL) 86 FI warning lamp (MIL) flashes 8x long, 6x short...
Page 175 BLINK CODE Blink code FI of warning lamp (MIL) 92 FI warning lamp (MIL) flashes 9x long, 2x short Error level condition DBW throttle actuator control IC - stuck open Blink code FI of warning lamp (MIL) 93 FI warning lamp (MIL) flashes 9x long, 3x short Error level condition CPU mutual - surveillance error Blink code FI of warning lamp...
Page 176: Technical Data
TECHNICAL DATA 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 177: Engine Tightening Torques
TECHNICAL DATA 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 Alternator 12 V, 224 W Spark plug Inside spark plug NGK LKAR8BI-9 Outside spark plug NGK LMAR7A-9 Spark plug electrode gap...
Page 178 TECHNICAL DATA Screw, gear sensor 5 Nm (3.7 lbf ft) Loctite ® 243™ – Screw, oil filter cover 6 Nm (4.4 lbf ft) Screw, oil pump cover, top 6 Nm (4.4 lbf ft) Loctite ® 243™ Loctite ® 243™ Plug, vacuum connection 10 Nm (7.4 lbf ft) –...
Page 179 TECHNICAL DATA Screw, thermostat housing 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, timing chain guide rail 10 Nm (7.4 lbf ft) Loctite ® 2701™ Screw, timing chain tensioning rail 10 Nm (7.4 lbf ft) Loctite ® 2701™ – Screw, valve cover 10 Nm (7.4 lbf ft) –...
Page 180: Capacities
TECHNICAL DATA – Screw, unlocking of timing chain ten- M10x1 10 Nm (7.4 lbf ft) sioner – Spark plug outside M10x1 11 Nm (8.1 lbf ft) – Spark plug inside M12x1.25 18 Nm (13.3 lbf ft) – Coolant temperature sensor on cylinder M12x1.5 12 Nm (8.9 lbf ft) head...
Page 181: Coolant
TECHNICAL DATA 22.3.2 Coolant Coolant 1.20 l (1.27 qt.) Coolant ( p. 188) 22.3.3 Fuel Total fuel tank capacity, approx. 12 l (3.2 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 190) Fuel reserve, approx. 2.5 l (2.6 qt.) 22.4 Chassis Frame...
Page 182: Electrical System
TECHNICAL DATA Rear 4.5 mm (0.177 in) Tire air pressure, solo Front 2.0 bar (29 psi) Rear 2.0 bar (29 psi) Tire air pressure with passenger / fully loaded Front 2.0 bar (29 psi) Rear 2.2 bar (32 psi) Secondary drive ratio 16:42 Chain 5/8 x 1/4”...
Page 183: Tires
160/60 R 17 M/C 69H TL Continental Conti Attack SM Continental Conti Attack SM The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork Fork part number 14.18.8N.12...
Page 184: Shock Absorber
TECHNICAL DATA Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring length with preload spacer(s) 463 mm (18.23 in) Spring rate Medium (standard) 5.3 N/mm (30.3 lb/in) Air chamber length mm (4.33 +0.79...
Page 185: Chassis Tightening Torques
TECHNICAL DATA Standard 20 clicks Sport 15 clicks Full load capacity 15 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload 20 mm (0.79 in) Spring rate Medium (standard) 80 N/mm (457 lb/in) Hard 85 N/mm (485 lb/in) Spring length...
Page 186 TECHNICAL DATA – Screw, side stand switch EJOT 2 Nm (1.5 lbf ft) – Screw, SLS valve EJOT 2 Nm (1.5 lbf ft) – Fitting, side stand switch 2 Nm (1.5 lbf ft) – Spoke nipple, front wheel M4.5 4 Nm (3 lbf ft) –...
Page 187 TECHNICAL DATA – Screw, air filter box top 2 Nm (1.5 lbf ft) Screw, ball joint of push rod on foot 10 Nm (7.4 lbf ft) Loctite ® 243™ brake cylinder – Screw, brake assembly 5 Nm (3.7 lbf ft) –...
Page 188 TECHNICAL DATA – Screw, bottom triple clamp 12 Nm (8.9 lbf ft) – Screw, chain sliding piece 15 Nm (11.1 lbf ft) Screw, connection lever on frame 30 Nm (22.1 lbf ft) Loctite ® 243™ Loctite ® 243™ Screw, foot brake lever 25 Nm (18.4 lbf ft) –...
Page 189 TECHNICAL DATA Screw, bottom shock absorber 45 Nm (33.2 lbf ft) Loctite ® 243™ – Screw, engine bearer on frame 45 Nm (33.2 lbf ft) Screw, handlebar support 40 Nm (29.5 lbf ft) Loctite ® 243™ Loctite ® 243™ Screw, side stand 35 Nm (25.8 lbf ft) Screw, top shock absorber 45 Nm (33.2 lbf ft)
Page 190: Substances
SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®...
Page 191 JASO T903 MA ( p. 193) – SAE ( p. 193) (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 192 SUBSTANCES Recommended supplier Motorex ® – Power Synt 4T Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 193) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding proper- ties.
Page 193: Auxiliary Substances
AUXILIARY SUBSTANCES Chain cleaner Recommended supplier Motorex ® – Chain Clean Chain lube for road use Guideline Recommended supplier Motorex ® – Chainlube Road Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Long-life grease Recommended supplier Motorex ® – Bike Grease 2000 Motorcycle cleaner Recommended supplier...
Page 194 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 195: Standards
STANDARDS JASO T903 MA Different technical development directions required a separate specification for 4-stroke motorcycles – the JASO T903 MA standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifica- tion.
Page 196: Index Of Special Terms
INDEX OF SPECIAL TERMS Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces Malfunction indicator lamp Indicator lamp that supports vehicle diagnostics through flash codes On-board diagnosis Vehicle system that monitors emission- and safety-related values...
Page 197: List Of Abbreviations
LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...
Page 198: List Of Symbols
LIST OF SYMBOLS 28.1 Red symbols Red symbols indicate an error condition that requires immediate intervention. The temperature warning lamp lights up red – The coolant temperature has reached a critical value. The oil pressure warning lamp lights up red – The oil pressure is too low. The battery warning lamp lights up red –...
Page 199 LIST OF SYMBOLS The idling speed indicator lamp lights up green – The transmission is shifted to idle. The high beam indicator lamp lights up blue – The high beam is switched on.
Page 200: Index
INDEX rear brake, checking ......101 INDEX Brakes ........52 ABS .
Page 201 INDEX display ........30 Engine number ........21 function buttons .
Page 202 INDEX Fork protector Implied warranty ....... . . 14 installing ........75 Intended use .
Page 203 INDEX Oil screens cleaning ......150, 153 Safe operation ........11 Operating substances .
Page 204 INDEX rear right ........18 Technical data Warranty .
Page 205 *3213548en* 3213548en 09/2016 KTM Sportmotorcycle GmbH Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com...

KTM 690 SMC R 2017 Owner's Manual

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