KTM 690 Enduro R AUS 2012 Owner's Manual
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KTM 690 Enduro R AUS 2012 Owner's Manual

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OWNER'S MANUAL
2012
690 Enduro R EU
690 Enduro R AUS/UK
Art. no. 3211787en

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Summary of Contents for KTM 690 Enduro R AUS 2012

  • Page 1 OWNER'S MANUAL 2012 690 Enduro R EU 690 Enduro R AUS/UK Art. no. 3211787en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to buy a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you DEAR KTM CUSTOMER enormous pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment in riding this vehicle! Enter the serial numbers of your vehicle below.
  • Page 4 Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Setting the clock .............. 27 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........7 Combination instrument - display ODO ....... 28 IMPORTANT INFORMATION ........... 8 Combination instrument - setting/resetting TRIP 1....28 VIEW OF VEHICLE..............12 Combination instrument - setting/resetting TRIP 2....29 View of vehicle, front left (example)........
  • Page 6 TABLE OF CONTENTS TUNING THE CHASSIS............54 Installing the air filter ..........74 Fork/shock absorber ............54 Checking the chain for dirt ..........75 Adjusting the compression damping of the fork ....54 Cleaning the chain............75 Adjusting the rebound damping of the fork......55 Checking the chain tension ..........
  • Page 7 TABLE OF CONTENTS Checking the basic position of the shift lever..... 144 Removing rear wheel ..........108 Adjusting the basic position of the shift lever ....144 Installing the rear wheel ..........109 SERVICE WORK ON THE ENGINE ........146 Checking the rear hub rubber dampers ......
  • Page 8 TABLE OF CONTENTS TECHNICAL DATA - SHOCK ABSORBER ......176 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ..178 SUBSTANCES..............182 AUXILIARY SUBSTANCES........... 186 STANDARDS..............188 INDEX ................189...

  • 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 serviced opti- mally by specially trained experts using the specialist tools required.

  • Page 10: Important Information

    Warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 11: Spare Parts, Accessories

    Spare parts, accessories For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.
  • Page 12 IMPORTANT INFORMATION – Switch off the engine and remove the ignition key. – Use straps or other suitable devices to secure the motorcycle against accidents or falling over. 401448-01 Environment Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential problem for the environment and can lead to conflicts with other persons.
  • Page 13 IMPORTANT INFORMATION Grades of risks Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

  • Page 14: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) 601762-10...
  • Page 15 VIEW OF VEHICLE Hand brake lever ( p. 19) Clutch lever ( p. 19) Handrails ( p. 33) Filler cap Engine number ( p. 17) Shift lever ( p. 34) Side stand ( p. 35) Seat release ( p. 32) Compression damping of the shock absorber ( p.

  • Page 16: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) 601763-10...
  • Page 17 VIEW OF VEHICLE Light switch ( p. 20) Turn signal switch ( p. 21) Horn button ( p. 21) Ignition/steering lock ( p. 23) Combination instrument ( p. 23) Emergency OFF switch ( p. 22) Electric starter button ( p. 22) Throttle grip ( p.

  • Page 18: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right. 601764-10 Type label The type label is located on the right side of the frame. 601765-10...

  • Page 19: Engine Number

    SERIAL NUMBERS Engine number The engine number is stamped on the left side of the engine under the engine sprocket. 100211-10 Key number The key number can be found on the KEYCODECARD. Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place.

  • Page 20: Fork Part Number

    SERIAL NUMBERS Fork part number The fork part number is stamped on the inner side of the fork stub. 601780-10 Shock absorber part number The shock absorber part number is on the left of the shock absorber. 101048-10...

  • Page 21: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 601766-10 Hand brake lever The hand break lever is fitted on the right side of the handlebar. The hand brake lever operates the front brake. 601767-10...

  • Page 22: Throttle Grip

    CONTROLS Throttle grip The throttle grip is fitted on the right side of the handlebar. 601767-11 Light switch The light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is turned downwards. In this position, the low beam and tail light are switched on.

  • Page 23: Turn Signal Switch

    CONTROLS Turn signal switch The turn signal switch is fitted on the left side of the handlebar. Possible states Turn signal off Turn signal light, left, on – Turn signal switch pressed to the left. The turn signal switch returns automatically to the central position after use. Turn signal light, right, on –...

  • Page 24: 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 25: 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 26: Combination Instrument - Function Buttons

    CONTROLS Combination instrument - function buttons 5.11 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 27: Combination Instrument - Display

    CONTROLS The oil pressure warning lamp lights up red – The oil pressure is too low. FI warning lamp (MIL) lights up/flashes orange – The OBD (onboard diagno- sis) has identified an emissions- or safety-critical fault. The battery warning lamp lights up red – The voltage in the vehicle system is too low.

  • Page 28: Combination Instrument - Speedometer

    CONTROLS Combination instrument - speedometer 5.14 The speed is shown in kilometers per hour km/h or in miles per hour mph. 400838-10 Setting kilometers or miles 5.15 Info If you change the unit, the value is retained and converted accordingly. Making the setting according to the country.

  • Page 29: Combination Instrument - Time

    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 pressed until the display mode changes from km/h to mph or from mph to km/h.

  • Page 30: Combination Instrument - Display Odo

    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 31: Combination Instrument - Setting/Resetting 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. 400840-01 Combination instrument - setting/resetting TRIP 2 5.20...

  • Page 32: Combination Instrument - Trip F Display

    CONTROLS Combination instrument - TRIP F display 5.21 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. 400842-01 Combination instrument - coolant temperature indicator 5.22...

  • Page 33: Opening The Filler Cap

    CONTROLS Opening the filler cap 5.23 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 34: Closing Filler Cap

    CONTROLS Closing filler cap 5.24 – Put the filler cap back on and turn the ignition key 90° clockwise. – Remove the ignition key and fold down the cover. 601771-01 Seat release 5.25 The seat can be released using strap 601772-10...

  • Page 35: Handrails

    CONTROLS Handrails 5.26 The handrails are used for moving the motorcycle around. When you have a passenger, the passenger can hold on the handrails during the journey. 601773-10 Passenger footrests 5.27 The passenger footrests can be folded up and down. Possible states Passenger footrests folded up –...

  • Page 36: Shift Lever

    CONTROLS Shift lever 5.28 The shift lever is mounted on the left side of the engine. 100215-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 100212-10...

  • Page 37: Foot Brake Lever

    CONTROLS Foot brake lever 5.29 Foot brake lever is located in front of the right footrest. The rear brake is engaged with the foot brake lever. 100232-10 Side stand 5.30 The side stand is located on the left side of the vehicle. The side stand is used for parking the motorcycle.

  • Page 38: Preparing For Use

    The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle. Warning Danger of accidents Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels. – Only tires/wheels approved by KTM and with the corresponding speed index should be used. Warning Danger of accidents Reduced road grip with new tires. –...

  • Page 39: 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 record at vehicle handover.

  • Page 40: Loading The Vehicle

    PREPARING FOR USE Guideline Maximum engine speed During the first: 1,000 km (621.4 mi) 6,000 rpm After the first: 1,000 km (621.4 mi) 7,800 rpm – Avoid fully opening the throttle! Loading the vehicle Warning Danger of accidents Unstable handling characteristics. –...
  • Page 41 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 in the dark. Check that your baggage is fixed properly at regular intervals.

  • Page 42: 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 43: Starting

    RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 44: Starting Off

    RIDING INSTRUCTIONS Info Do not press the electric starter button until the function test of the combination instrument is finished. When starting, DO NOT open the throttle. If you open the throttle during the start- ing procedure, fuel is not injected by the engine management system and the engine cannot start.
  • Page 45 RIDING INSTRUCTIONS Warning Danger of accidents Malfunctions caused by incorrect ignition key position. – Do not change the ignition key position during a journey. Warning Danger of accidents Distraction from traffic activity by adjustments to the vehicle. – Make all adjustments when the vehicle is at a standstill. Warning Risk of injury Falling off of the passenger.
  • Page 46 If you continue with the coolant temperature warning lamp alight, you may have engine failure. Info If unusual noises arise during operation, stop immediately, park the vehicle properly and contact an authorized KTM workshop.
  • Page 47 RIDING INSTRUCTIONS – When conditions allow (incline, road situation, etc.), you can shift into a higher gear. – Release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle. Info You can see the positions of the 6 forward gears in the figure.

  • Page 48: Braking

    Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. – Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Failure of brake system.

  • Page 49: Stopping, Parking

    RIDING INSTRUCTIONS Warning Danger of accidents Delayed brake action on salted roads. – There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the deposits from the discs by carefully applying the brakes. –...

  • Page 50: Refueling

    RIDING INSTRUCTIONS – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first. Note Material damage Damage and destruction of components by excessive load. –...
  • Page 51 – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards.
  • Page 52 RIDING INSTRUCTIONS – Press the SET button for two seconds. The fuel level warning lamp switches off. TRIP F is set to 0.0 and the display returns to the previous display mode. Info If you do not press the SET button , the reset takes place automatically after about three minutes.

  • Page 53: Service Schedule

    Check that the electrical equipment is functioning correctly. • • • • • • Read out the fault memory using the KTM diagnostics tool. • • Check the measured service values with the KTM diagnostics tool. • • • Change the engine oil and filter, clean the oil screens.
  • Page 54 Final check: Check the vehicle for roadworthiness and take a test ride. • • • • • • Read out the fault memory using the KTM diagnostics tool after a test ride. • • • Make the service entry in KTM DEALER.NET and in the service record.
  • Page 55 SERVICE SCHEDULE K10N: Once after 1,000 km (621.4 mi) K100A: Every 10,000 km (6,214 mi) or annually or after every sporting use K200A: Every 20,000 km (12,428 mi) or every 2 years...

  • Page 56: Tuning The Chassis

    TUNING THE CHASSIS 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 . You can find the table on the underside of the seat.

  • Page 57: 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. Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork rebound behavior. –...

  • Page 58: Compression Damping Of The Shock Absorber

    Adjusting the low-speed compression damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)

  • Page 59: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    Adjusting the high-speed compression damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)

  • Page 60: Adjusting The Rebound Damping Of The Shock Absorber

    Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)

  • Page 61: Measuring The Unloaded Rear Wheel Sag

    TUNING THE CHASSIS – Turn adjusting screw clockwise up to the last perceptible click. – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks 100247-10 Full payload 10 clicks...

  • Page 62: Checking The Static Sag Of The Shock Absorber

    TUNING THE CHASSIS Checking the static sag of the shock absorber – Measure distance of rear wheel unloaded. ( p. 59) – Hold the motorcycle upright with the aid of an assistant. – Measure the distance between the rear axle and the fixed point again. 0 0 A –...

  • Page 63: Checking The Riding Sag Of The Shock Absorber

    Adjusting the spring preload of the shock absorber 9.11 Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)
  • Page 64 TUNING THE CHASSIS Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. Preliminary work – Raise the motorcycle with the work stand. – Remove the shock absorber. – After removing the shock absorber, clean it thoroughly.

  • Page 65: Adjusting The Riding Sag

    TUNING THE CHASSIS Adjusting the riding sag 9.12 Preliminary work – Raise the motorcycle with the work stand. – Remove the shock absorber. – After removing the shock absorber, clean it thoroughly. Main work – Choose and mount a suitable spring. Guideline Spring rate Medium (standard)

  • Page 66: Handlebar Position

    TUNING THE CHASSIS Handlebar position 9.13 On the upper triple clamp, there are 2 holes at a distance to each other. Distance between holes 15 mm (0.59 in) The holes on the handlebar support are placed at a distance from the center. Distance between holes 3.5 mm (0.138 in)
  • Page 67 TUNING THE CHASSIS – Position the handlebar. Info Make sure cables and wiring are positioned correctly. – Position the handlebar clamp. Fit and evenly tighten the four screws Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft)

  • Page 68: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS Raising the motorcycle with the lift stand 10.1 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle using the underride guard under the motorcycle. The wheels must no longer touch the ground.

  • Page 69: Bleeding The Fork Legs

    SERVICE WORK ON THE CHASSIS Bleeding the fork legs 10.3 Preliminary work – Lean the motorcycle on the side stand. Main work – Remove bleeder screws briefly. Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. Info Carry out this action on both fork legs.

  • Page 70: Loosening The Fork Protection

    SERVICE WORK ON THE CHASSIS Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. – Clean and oil the dust boots and inner fork tube of both fork legs.

  • Page 71: Positioning The Fork Protection

    Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become damaged over time.

  • Page 72: Adjusting The Play Of The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: –...
  • Page 73 SERVICE WORK ON THE CHASSIS – Loosen screw . Remove screw – Loosen and retighten screw Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) – Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. –...

  • Page 74: Removing The Seat

    SERVICE WORK ON THE CHASSIS Removing the seat 10.9 – Pull on strap and raise the rear of the seat at the same time. – Pull back the seat and lift it off. 601772-10 Mounting the seat 10.10 601782-10 – Hook slot of the seat onto screw , press the rear downward and at the same time push it forward.

  • Page 75: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS Removing the air filter 10.11 Preliminary work – Remove the seat. ( p. 72) Main work – Remove screws . Remove filter box top 601783-10 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine.

  • Page 76: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS Installing the air filter 10.12 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 If the air filter is not correctly mounted, dust and dirt can enter the engine and cause damage.

  • Page 77: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS Checking the chain for dirt 10.13 – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 75) 400678-01 Cleaning the chain 10.14 Warning Danger of accidents Oil or grease on the tires reduces their grip. –...

  • Page 78: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS Info The service life of the chain depends largely on its maintenance. – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( p.

  • Page 79: Adjusting The Chain Tension

    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 80 SERVICE WORK ON THE CHASSIS Preliminary work – Check the chain tension. ( p. 76) 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 the left and right adjusting screws so that the markings on the left and right...

  • Page 81: Check The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

    SERVICE WORK ON THE CHASSIS Check the chain, rear sprocket, engine sprocket and chain guide 10.17 Preliminary work – Raise the motorcycle with the lift stand. ( p. 66) Main work – Shift gear to neutral. – Check the rear sprocket and engine sprocket for wear. »...
  • Page 82 SERVICE WORK ON THE CHASSIS – Pull on the upper section of the chain with the specified weight Guideline Weight of chain wear measurement 15 kg (33 lb.) 0 0 A – Measure distance of 18 chain links in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at differ- ent chain positions.
  • Page 83 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with or below the chain sliding guard: – Replace the chain sliding guard. – Check that the chain sliding guard is firmly seated. »...
  • Page 84 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 85 SERVICE WORK ON THE CHASSIS – Check that the chain guide is firmly seated. » If the chain guide is loose: – Tighten the chain guide. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 101068-01 Subsequent work – Remove the motorcycle from the lift stand. ( p.

  • Page 86: Adjusting Chain Guide

    SERVICE WORK ON THE CHASSIS Adjusting chain guide 10.18 – Remove screws . Take off the chain guide. Condition Number of teeth: ≤ 44 teeth – Insert nut in hole . Position the chain guide. – Mount and tighten screws Guideline Screw, chain guide 8 Nm (5.9 lbf ft)

  • Page 87: Adjusting Basic Position Of Clutch Lever

    SERVICE WORK ON THE CHASSIS Adjusting basic position of clutch lever 10.19 Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar. The range of adjustment is limited.

  • Page 88: Removing The Engine Guard

    SERVICE WORK ON THE CHASSIS – Remove screws – Remove cover with membrane – Check the fluid level. Fluid level under top level of container 4 mm (0.16 in) » If the level of the coolant does not meet specifications: –...

  • Page 89: Installing The Engine Guard

    SERVICE WORK ON THE CHASSIS Installing the engine guard 10.22 – Slide the engine guard into holders at the rear. – Position the engine guard. Mount and tighten screws. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 100199-10...

  • Page 90: Brakes

    BRAKES Checking the free travel of the hand brake lever 11.1 Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up in the front brake circuit. The front brake can fail due to overheating.

  • Page 91: Checking The Brake Discs

    Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (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 92: Checking The Front Brake Fluid Level

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 93: Adding Front Brake Fluid

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 94: Checking The Front Brake Linings

    11.6 Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. – If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly...

  • Page 95: Changing The Front Brake Linings

    If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)
  • Page 96 Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin- ings.
  • Page 97 BRAKES – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Press the brake caliper onto the brake disc by hand in order to push back the brake pis- tons.
  • Page 98 BRAKES – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 400418-10 – Insert the brake linings, insert the bolt and mount the cotter pin. – Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

  • Page 99: Checking The Free Travel Of Foot Brake Lever

    BRAKES Checking the free travel of foot brake lever 11.8 Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to over- heating.

  • Page 100: Checking Rear Brake Fluid Level

    If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

  • Page 101: Adding Rear Brake Fluid

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.
  • Page 102 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to 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

    – Change the rear brake linings. p. 101) 100260-10 Changing the rear brake linings 11.13 Warning Danger of accident Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.)
  • Page 104 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
  • Page 105 BRAKES Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.
  • Page 106 BRAKES – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 400419-11 – Insert the brake linings, insert the bolt and mount the cotter pin. – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

  • Page 107: Wheels, Tires

    WHEELS, TIRES Removing the front wheel 12.1 Preliminary work – Raise the motorcycle with the lift stand. ( p. 66) Main work – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons.

  • Page 108: Installing The Front Wheel

    WHEELS, TIRES – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. Info Do not pull the hand brake lever when the front wheel is removed. Always lay the wheel down in such a way that the brake disc is not damaged. 601809-10 –...
  • Page 109 WHEELS, TIRES – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Replace the wheel bearing. – Clean and grease the shaft seal rings and bearing surface of the distance bush- ings.

  • Page 110: Removing Rear Wheel

    WHEELS, TIRES Removing rear wheel 12.3 Preliminary work – Raise the motorcycle with the lift stand. ( p. 66) Main work – Press the brake caliper by hand on to the brake disc in order to press back the brake piston.

  • Page 111: Installing The Rear Wheel

    WHEELS, TIRES Installing the rear wheel 12.4 Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Danger of accidents No braking effect when operating the rear brake.

  • Page 112: 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. – Install the wheel spindle, the chain adjusters and the nut. Guideline In order that the rear wheel is correctly aligned, the markings on the left and right chain adjusters must be in the same position relative to the reference marks Info Mount the left and right chain adjusters...
  • Page 113 WHEELS, TIRES Main work – Check bearing » If the bearing is damaged or worn: – Replace the bearings. – Check rubber dampers of the rear hub for damage and wear. » If the rubber dampers of the rear hub are damaged or worn: –...

  • Page 114: Checking The Tire Condition

    Danger of accidents Uncontrollable vehicle handling in the event of a flat tire. – In the interest of safety, replace damaged or worn tires immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.

  • Page 115: Checking The Tire Air Pressure

    DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture. KTM recommends that the tires are changed regardless of the actual wear, at the latest after 5 years.

  • Page 116: Checking The Spoke Tension

    Correct the tire pressure. – Mount the dust cap. Checking the spoke tension 12.8 Warning Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.)
  • Page 117 WHEELS, TIRES Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes. If the spokes are too tight, they can break due to local overload. Check the spoke tension regularly, especially on a new motorcycle. – Briefly strike each spoke with a screwdriver blade.

  • Page 118: Electrical System

    ELECTRICAL SYSTEM Removing the battery 13.1 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: Installing The Battery

    ELECTRICAL SYSTEM Installing the battery 13.2 Main work – Slide the battery into the battery rack. Info The battery terminals must be at the rear. – Attach the positive cable and mount positive terminal cover – Position retaining bracket – Mount and tighten screws 601812-11 Guideline...

  • Page 120: Recharging The Battery

    – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 121 ELECTRICAL SYSTEM Info Even when there is no load on the battery, it still loses power steadily. The charge state and the type of charge 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 122 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 Never remove lid Charge the battery with a maximum of 10% of the capacity specified on the bat-...

  • Page 123: Changing The Main Fuse

    ELECTRICAL SYSTEM Changing the main fuse 13.4 Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers in the vehicle. It is in the housing of the starter relay next to the battery. Preliminary work –...

  • Page 124: Changing Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM – Remove a defective main fuse with needle nose pliers. – Install a new main fuse. Fuse (58011109130) ( p. 173) Info A reserve fuse is located in the starter relay. – Check that the electrical equipment is functioning properly. –...
  • Page 125 ELECTRICAL SYSTEM Main work – Open fuse box cover 601791-11 – Remove the defective fuse. Guideline Fuse 1 - 10 A - ignition, combination instrument Fuse 2 - 10 A - clock, ignition (EFI control unit) Fuse 3 - 10 A - throttle valve control unit Fuse 4 - 10 A - fuel pump Fuse 5 - 10 A - radiator fan Fuse 6 - 10 A - horn, brake light, turn signal...

  • Page 126: Removing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. – Replace with a spare fuse of the right rating. Fuse (75011088010) ( p.
  • Page 127 ELECTRICAL SYSTEM Main work – Cover the fender with a cloth to protect it from damage. – Remove screws on the left and right. – Tip the headlight mask forward and pull it off in an upward direction. 601793-10 – Disconnect the connectors of turn signals and headlight –...

  • Page 128: Installing The Headlight Mask With The Headlight

    ELECTRICAL SYSTEM Installing the headlight mask with the headlight 13.7 – Connect the connectors of headlight and turn signal lights – Check lighting function. 601794-11 – Remove the cloth from the fender, attach the headlight mask to points on the fender and swing it up to the steering head.

  • Page 129: Changing The Headlight Bulb

    ELECTRICAL SYSTEM – Position brake-hose guide . Mount and tighten screws Guideline Screw, headlight mask 5 Nm (3.7 lbf ft) 601793-11 Changing the headlight bulb 13.8 Note Damage to reflector Reduced luminance. – 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 130: Changing The Parking Light Bulb

    ELECTRICAL SYSTEM Main work – Pull off connector – Take off rubber cap of the headlight bulb. 600610-10 – Detach spring bar – Remove headlight bulb – Insert a new headlight bulb into the headlight housing. Headlight (H4 / socket P43t) ( p.
  • Page 131 ELECTRICAL SYSTEM Preliminary work – Switch off all power consumers and switch off the engine. – Remove the headlight mask with the headlight. ( p. 124) Main work – Remove rubber cap 600610-12 – Pull bulb socket out of the reflector. –...

  • Page 132: Changing The Turn Signal Bulb

    ELECTRICAL SYSTEM Changing the turn signal bulb 13.10 Note Damage to reflector Reduced luminance. – 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 133: Checking The Headlight Setting

    ELECTRICAL SYSTEM Checking the headlight setting 13.11 – Stand 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. 0 0 A –...
  • Page 134 ELECTRICAL SYSTEM Main work – Turn adjusting screw to adjust the headlight range. Guideline For a motorcycle with rider, the light/dark boundary must be exactly on the lower mark (made in: Checking headlight adjustment). Info Turn clockwise to increase the headlight range; turn counterclockwise to reduce the headlight range.

  • Page 135: Cooling System

    COOLING SYSTEM Cooling system 14.1 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 radi- ator cap . The heat expansion causes the surplus coolant to flow into the compensating tank .
  • Page 136 COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.

  • Page 137: Checking The Coolant Level

    COOLING SYSTEM – Screw off the radiator cap – Check antifreeze of coolant. −25… −45 °C (−13… −49 °F) » If the antifreeze of the coolant does not meet specifications: – Correct the antifreeze of the coolant. – Check the coolant level in the radiator. The radiator must be completely filled.
  • Page 138 COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.

  • Page 139: Draining The Coolant

    COOLING SYSTEM Alternative 2 Coolant (mixed ready to use) ( p. 182) – Mount the radiator cap. Draining the coolant 14.4 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 140: Filling The Cooling System

    COOLING SYSTEM Main work – Stand the motorcycle upright. – Place a suitable container under the engine. – Remove screw . Take off the radiator cap. – Completely drain the coolant. – Mount screw with a new seal ring and tighten it. Guideline Plug, drain hole of water pump M10x1...
  • Page 141 COOLING SYSTEM – Stand the motorcycle on its side stand on a horizontal surface. – Remove radiator cap 601799-11 – Refill the coolant. Alternative 1 Coolant ( p. 182) Alternative 2 Coolant (mixed ready to use) ( p. 182) – Fill the radiator completely with coolant.
  • Page 142 COOLING SYSTEM – Start the engine and run it until the 5th bar of the temperature indicator lights up. – Switch off the engine and allow it to cool down. – After the engine has cooled down, check the coolant level in the radiator and in the compensating tank again and add more coolant if necessary.

  • Page 143: Tuning The Engine

    TUNING THE ENGINE Checking the play in the throttle cable 15.1 – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip backwards and forwards to ascertain the play in the throttle cable. Throttle cable play 3…...

  • Page 144: Adjusting The Play In The Throttle Cable

    15.2 – Move the handlebar to the straight-ahead position. – Use the KTM diagnostics tool to set the motor drive to the basic position. – Loosen counter nut – Set the play in the throttle cable by turning the adjusting screw...
  • Page 145 TUNING THE ENGINE – Turn the adjusting wheel until the desired digit is next to marking Set the Map‑Select switch to Soft. – Set the adjusting wheel to position 1. Soft – reduced homologated peak performance for better driveability. Set the Map‑Select switch to Advanced. –...

  • Page 146: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE Checking the basic position of the shift lever 15.4 – Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the shift lever. Distance between shift lever and upper 10…...
  • Page 147 TUNING THE ENGINE – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gear- ing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure.

  • Page 148: Service Work On The Engine

    SERVICE WORK ON THE ENGINE Checking the engine oil level 16.1 Info The engine oil level must be checked when the engine is warm. Condition The engine is at operating temperature. Preliminary work – Stand the motorcycle upright on a horizontal surface. Main work –...

  • Page 149: Changing The Engine Oil And Filter, Cleaning The Oil Screens

    SERVICE WORK ON THE ENGINE Changing the engine oil and filter, cleaning the oil screens 16.2 – Drain the engine oil. p. 147) – Remove the oil filter. p. 148) – Clean the oil screens. p. 150) – Install the oil filter. p.

  • Page 150: Removing The Oil Filter

    SERVICE WORK ON THE ENGINE Main work – Place a suitable container under the engine. – Remove the oil drain plug with the magnet and seal ring. – Completely drain the engine oil. 100200-10 – Thoroughly clean the oil drain plug with a magnet. –...
  • Page 151 SERVICE WORK ON THE ENGINE Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Preliminary work – Place a suitable container under the engine. Main work –...

  • Page 152: Cleaning The Oil Screens

    SERVICE WORK ON THE ENGINE Cleaning the oil screens 16.5 Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 153 SERVICE WORK ON THE ENGINE – Remove plug with oil screen and the O-rings. – Completely drain the remaining engine oil. – Thoroughly clean the parts and sealing area. 100206-10 – Position oil screen with the O-rings. – Mount and tighten screw plug with the O-ring.

  • Page 154: Installing The Oil Filter

    SERVICE WORK ON THE ENGINE Installing the oil filter 16.6 – 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) 100204-10 Filling up with engine oil 16.7...

  • Page 155: Adding Engine Oil

    SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
  • Page 156 SERVICE WORK ON THE ENGINE – Install and tighten the oil filler plug with the O-ring. Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 157: Cleaning, Care

    CLEANING, CARE Cleaning the motorcycle 17.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 158 CLEANING, CARE – After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly. Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes. – Clean or dry dirty or wet brakes by riding and braking gently. –...

  • Page 159: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE Universal oil spray ( p. 187) Checks and maintenance steps for winter operation 17.2 Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If the vehicle was operated in road salt, clean it with cold water after riding.

  • Page 160: Storage

    – 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 lift stand. ( p. 66) – Cover the motorcycle with a tarp or similar cover that is permeable to air.

  • Page 161: 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 162: Troubleshooting

    Clean the socket connector and treat it with con- oxidized tact spray. – 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 163 Air in cooling system Fill the cooling system. p. 138) – 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 164 TROUBLESHOOTING Faults Possible cause Action – Time is not (correctly) displayed Fuse 2 blown Change the fuses of individual power consumers. p. 122) – Set the clock. ( p. 27) – Battery discharged Ignition not switched off when vehicle Recharge the battery. p.

  • Page 165: 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) 06 FI warning lamp (MIL) flashes briefly 6x Error level condition Throttle position sensor circuit A - input signal too low Blink code FI of warning lamp...
  • Page 166 BLINK CODE Blink code FI of warning lamp (MIL) 14 FI warning lamp (MIL) flashes 1x long, 4x short Error level condition Ambient air pressure sensor - input signal too low Ambient air pressure sensor - input signal too high Blink code FI of warning lamp (MIL) 15 FI warning lamp (MIL) flashes 1x long, 5x short...
  • Page 167 BLINK CODE Blink code FI of warning lamp (MIL) 26 FI warning lamp (MIL) flashes 2x long, 6x short Error level condition Motor drive hall sensor - circuit fault Blink code FI of warning lamp (MIL) 37 FI warning lamp (MIL) flashes 3x long, 7x short Error level condition Ignition coil 1, cylinder 1 - circuit fault Blink code FI of warning lamp...
  • Page 168 BLINK CODE Blink code FI of warning lamp (MIL) 58 FI warning lamp (MIL) flashes 5x long, 8x short Error level condition EPT motor drive relay permission - signal fault Blink code FI of warning lamp (MIL) 60 FI warning lamp (MIL) flashes 6x long Error level condition Motor drive - circuit fault Blink code FI of warning lamp...

  • Page 169: Technical Data - Engine

    TECHNICAL DATA - 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 12.5:1 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 170: Capacity - Engine Oil

    TECHNICAL DATA - ENGINE 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 NGK LKAR 8AI - 9 Spark plug electrode gap 0.9 mm (0.035 in) Cooling Water cooling, permanent circulation of coolant by water pump...

  • Page 171: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Oil hole plug EJOT 9 Nm (6.6 lbf ft) Loctite 243™ ® Screw, membrane fixation 2.5 Nm (1.84 lbf ft) Loctite 243™ – Hose clamp, intake flange 1.5 Nm (1.11 lbf ft) ® Oil nozzle for conrod bearing lubrication 2 Nm (1.5 lbf ft) Loctite...
  • Page 172 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Screw, locking lever 10 Nm (7.4 lbf ft) Loctite 243™ – Screw, rocker arm shaft 12 Nm (8.9 lbf ft) ® Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite 243™ ® Screw, shift lever 14 Nm (10.3 lbf ft) Loctite...
  • Page 173 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Oil hole plug M10x1 15 Nm (11.1 lbf ft) Loctite 243™ – Plug, drain hole of water pump M10x1 15 Nm (11.1 lbf ft) – Plug, oil bore for oil radiator M10x1 15 Nm (11.1 lbf ft) –...

  • Page 174: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS Frame Lattice frame made of chrome molybdenum steel tubing, powder- coated Fork WP Suspension 4860 MXMA Shock absorber WP Suspension 4618 with Pro‑Lever deflector Suspension travel Front 250 mm (9.84 in) Rear 250 mm (9.84 in) Brake system Front Disc brake with dual-piston brake caliper, floating...

  • Page 175: Lighting Equipment

    TECHNICAL DATA - CHASSIS Secondary drive ratio 15:45 Chain 5/8 x 1/4” X‑ring Steering head angle 63° Wheelbase 1,504±15 mm (59.21±0.59 in) Seat height unloaded 935 mm (36.81 in) Ground clearance unloaded 280 mm (11.02 in) Weight without fuel, approx. 142 kg (313 lb.) Maximum permissible front axle load 150 kg (331 lb.)

  • Page 176: Tires

    140/80 - 18 M/C 70R M+S TT To max.: 160 km/h (99.4 mph) Continental TKC 80 Continental TKC 80 Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 23.3 Total fuel tank capacity, approx. 12 l (3.2 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p.

  • Page 177: Technical Data - Fork

    TECHNICAL DATA - FORK Fork part number 14.18.7L.10 Fork WP Suspension 4860 MXMA Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring length with preload spacer(s) 472 mm (18.58 in)

  • Page 178: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 15.18.7L.10 Shock absorber WP Suspension 4618 with Pro‑Lever deflector Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1 turn Full payload 1 turn Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport...
  • Page 179 TECHNICAL DATA - SHOCK ABSORBER Fitted length 395 mm (15.55 in) Shock absorber oil ( p. 184) SAE 2.5...

  • Page 180: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw, chain guard EJOT 2 Nm (1.5 lbf ft) – Screw, combination instrument EJOT 1 Nm (0.7 lbf ft) – Screw, license plate holder, bottom EJOT 3 Nm (2.2 lbf ft) – Screw, side cover on spoiler EJOT 1 Nm (0.7 lbf ft) –...
  • Page 181 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw, pressure regulator 4 Nm (3 lbf ft) – Spoke nipple, rear wheel 3… 6 Nm (2.2… 4.4 lbf ft) – Remaining nuts, chassis 10 Nm (7.4 lbf ft) – Remaining screws on fuel tank 5 Nm (3.7 lbf ft) –...
  • Page 182 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ® Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite 2701 – Remaining nuts, chassis 25 Nm (18.4 lbf ft) – Remaining screws, chassis 25 Nm (18.4 lbf ft) – Screw, bottom triple clamp 12 Nm (8.9 lbf ft) –...
  • Page 183 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw, steering stem 20 Nm (14.8 lbf ft) – Screw, top triple clamp 17 Nm (12.5 lbf ft) ® Engine carrying screw 45 Nm (33.2 lbf ft) Loctite 243™ – Remaining nuts, chassis 45 Nm (33.2 lbf ft) –...

  • Page 184: Substances

    – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the correspond- ® ing properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...

  • Page 185: Engine Oil (Sae 10W/60)

    188) (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. KTM recommends Motorex products. Synthetic engine oil Supplier ® Motorex –...
  • Page 186 – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75 Shock absorber oil (SAE 2.5) (50180342S1)
  • Page 187 SUBSTANCES Super unleaded (ROZ 95/RON 95/PON 91) According to – DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e.

  • Page 188: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Protect & Shine...
  • Page 189 AUXILIARY SUBSTANCES Motorcycle cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Moto Clean 900 Off-road chain spray Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chainlube Offroad Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline –...

  • Page 190: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.

  • Page 191: Index

    INDEX rear brake, checking ......101 INDEX Brakes ........46 Accessories .
  • Page 192 INDEX setting kilometers or miles ..... . . 26 Engine oil speed display ....... . 26 adding .
  • Page 193 INDEX Fork protector positioning ....... . . 69 Ignition lock ........23 remove .
  • Page 194 INDEX removing ........72 Parking light bulb changing .
  • Page 195 INDEX right rear ........14 Storage .
  • Page 196 *3211787en* 3211787en 01/2012 Photo: Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

This manual is also suitable for:

690 enduro r eu 2012690 enduro r uk 2012

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