KTM 690 ENDURO EU Owner's Manual
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KTM 690 ENDURO EU Owner's Manual

Ktm owner's manual motorcycle 690 enduro eu, 690 enduro aus/uk
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OWNER'S MANUAL
2008
690 ENDURO EU
690 ENDURO AUS/UK
ART. NO. 3211239en

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Summary of Contents for KTM 690 ENDURO EU

  • Page 1 OWNER'S MANUAL 2008 690 ENDURO EU 690 ENDURO AUS/UK ART. NO. 3211239en...
  • Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, as well as printing and other errors.
  • Page 4 Reproduction, even in part, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) Within the meaning of 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

    CONTENTS CONTENTS MEANS OF REPRESENTATION ... 7 IMPORTANT NOTES ... 8 VIEW OF VEHICLE... 12 View of vehicle, front left side... 12 View of vehicle, rear right side ... 14 LOCATION OF SERIAL NUMBERS ... 16 Chassis number... 16 Type label... 16 Key number ...
  • Page 6 Important maintenance work to be carried out by an authorized KTM workshop..53 Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)... 55 MAINTENANCE WORK ON CHASSIS AND ENGINE ... 56 Jacking up the motorcycle ... 56 Removing the motorcycle from the work stand...
  • Page 7 Filling up with engine oil  Topping up engine oil ... 140 TROUBLESHOOTING... 141 FLASHING CODE ... 144 CLEANING... 147 Cleaning motorcycle ... 147 CONSERVATION FOR WINTER OPERATION ... 149 Conservation for winter operation ... 149 STORAGE ... 150 Storage... 150 Putting into operation after storage ...
  • Page 8 CONTENTS STANDARDS... 171 INDEX ... 172...

  • 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 done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.

  • Page 10: Important Notes

    Warranty The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.
  • Page 11 IMPORTANT NOTES Spare parts, accessories For your own safety, use only spare parts and accessories approved by KTM, and have these mounted only in an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
  • Page 12 Read this owner's manual carefully and completely before making your first trip. It contains a lot of information and tips to help you operate and handle your motorcycle. Only then will you find out how to customize the motorcycle ideally for your own use and how you...
  • Page 13 IMPORTANT NOTES – The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.

  • Page 14: View Of Vehicle

    VIEW OF VEHICLE 3 V IEW OF VEHICLE View of vehicle, front left side 100234-10...
  • Page 15 VIEW OF VEHICLE Hand brake lever Clutch lever Handrail Filler cap Seat Front brake caliper Shift lever Engine number Side stand Footrest Seat release strap...

  • Page 16: View Of Vehicle, Rear Right Side

    VIEW OF VEHICLE View of vehicle, rear right side 100235-10...
  • Page 17 VIEW OF VEHICLE Ignition/steering lock Rear mirror Light switch, flasher switch, horn Combination instrument Emergency OFF switch, electric starter button Throttle grip Chassis number Rear brake caliper Passenger footrest Shock absorber rebound damping Foot brake pedal Engine oil level viewer...

  • Page 18: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS 4 L OCATION OF SERIAL NUMBERS Chassis number 100217-10 Type label 100218-10 The chassis number  is stamped on the steering head on the right.  Type label  is located on the upper right frame tube below the seat. ...

  • Page 19: Key Number

    LOCATION OF SERIAL NUMBERS Key number 100179-10 Engine number 100211-10 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. The engine number  is stamped on the left side of the engine under the engine sprocket. ...

  • Page 20: Fork Part Number

    LOCATION OF SERIAL NUMBERS Fork part number 100214-10 Shock absorber part number 100216-10 The fork part number  is stamped on the inner side of the fork stub.  Shock absorber part number  can be viewed from the right side. ...

  • Page 21: Operating Elements

    OPERATING ELEMENTS 5 O PERATING ELEMENTS Clutch lever 100219-10 Hand brake lever 100220-10 The clutch lever  is fitted on the left side of the handlebar.  The clutch is hydraulically operated and self-adjusting. The hand break lever  is fitted on the right side of the handlebar. ...

  • Page 22: Light Switch

    OPERATING ELEMENTS Light switch 500020-01 Light switch 100222-10 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. High beam on – Light switch is turned upwards.

  • Page 23: Headlight Flasher Switch

    OPERATING ELEMENTS Headlight flasher switch 500020-11 Flasher switch 500021-10 The headlight flasher switch  is fitted on the left side of the handlebar.  Possible states • Headlight flasher switch in neutral position Headlight flasher switch pressed – In this position, the headlight flasher (high beam) •...

  • Page 24: Flasher Switch

    OPERATING ELEMENTS Flasher switch 100223-10 Horn 500021-11 The flasher switch  is fitted on the left side of the handlebar.  Possible states Flasher light off Flasher light, left, on – Flasher switch pressed to the right. The flasher switch returns automatically to the central position after use. Flasher light, right, on – Flasher switch pressed to the right.

  • Page 25: Horn

    OPERATING ELEMENTS Horn 100224-10 Emergency OFF switch 5.10 100225-10 The horn button  is fitted on the left side of the handlebar.  Possible states • Horn button  in neutral position pressed – The horn is operated in this position. • Horn button  The emergency OFF switch ...

  • Page 26: Electric Starter Button

    OPERATING ELEMENTS Electric starter button 5.11 100226-10 Ignition/steering lock 5.12 100221-10 The electric starter button  is fitted on the right side of the handlebar.  Possible states • Electric starter button  in basic position pressed – In this position, the electric starter is actuated. •...

  • Page 27: Combination Instrument

    OPERATING ELEMENTS Combination instrument 5.13 700116-01 Combination instrument - function buttons 5.14 700117-01 The combination instrument is attached in fromt of the handlebar. The combination instrument is divided into 4 function areas.  Function buttons  Tachometer  Indicator lights  Display ...

  • Page 28: Combination Instrument - Tachometer

    The red marking  shows the excess engine speed range.  The indicator lamps provide additional information on the operating state of the motorcycle. Possible states Flashing indicator flashes green in flash rhythm – Flasher light is switched Idling speed indicator lamp lights up green – Transmission is in neutral.

  • Page 29: Combination Instrument - Display

    OPERATING ELEMENTS Combination instrument - Display 5.17 700118-01 400404-01 Battery warning lamp lights up – Voltage in electrical system too low. When you switch on the ignition, all display segments light up for a second as a function test. LEnGTth Following the display function test, the wheel circumference LEnGth is shown for one sec- ond.

  • Page 30: Combination Instrument - Speed Display

    5.19 Info If you change the unit, the ODO value is retained and converted accordingly. Making the setting according to the country. The speed  is displayed in kilometers per hour km/h or miles per hour Mph.  Condition The motorcycle is standing.

  • Page 31: Combination Instrument - Time

    Mph to Km/h. Specification Activation duration of MODE button The time is shown in area  of the display.  Info The time must be adjusted after the battery is disconnected or the fuse is changed. Condition The motorcycle is standing. 10 s...

  • Page 32: Combination Instrument - Odo Display

    OPERATING ELEMENTS 700115-10 Combination instrument - ODO display 5.22 700120-01 Combination instrument - setting/resetting TRIP 1 display 5.23 Info The tripmaster TRIP 1 operates constantly and counts up to 999.9. You can use the tripmaster to measure trips or the distance between refuelling stops. After reaching 999.9, the tripmaster begins again at 0.0.

  • Page 33: Combination Instrument - Setting/Resetting Trip 2 Display

    OPERATING ELEMENTS 700121-01 Combination instrument - setting/resetting TRIP 2 display 5.24 Info The tripmaster TRIP 2 operates constantly and counts up to 999.9. You can use the tripmaster to measure trips or the distance between refuelling stops. After reaching 999.9, the tripmaster begins again at 0.0. 700122-01 –...

  • Page 34: Combination Instrument - Trip F Display

    OPERATING ELEMENTS Combination instrument - TRIP F display 5.25 700123-01 Combination instrument - coolant temperature indicator 5.26 700124-01 When the fuel level reaches the reserve mark, the display automatically changes to TRIP F and begins to count from 0.0, regardless of which display mode was previously active. Info Parallel to the TRIP F display, the fuel warning light begins to light up.

  • Page 35: Opening Filler Cap

    OPERATING ELEMENTS Opening filler cap 5.27 100227-10 Closing filler cap 5.28 100228-01 – Lift the cover of the filler cap  and insert the ignition key.  – Turn the ignition key 90° counterclockwise and remove the filler cap. Info The filler cap has a tank air vent system. –...

  • Page 36: Handrails

    Handrails 5.29 100229-10 Seat release 5.30 100230-10 The handrails  are used for moving the motorcycle around.  When you have a passenger, the passenger can hold on the handrails during the journey. The seat can be released using strap  ...

  • Page 37: Passenger Footrests

    OPERATING ELEMENTS Passenger footrests 5.31 100231-01 Shift lever 5.32 100215-10 The passenger footrests can be folded up and down. Possible states Passenger footrests folded up – For operation without a passenger. • Passenger footrests folded down – For operation with a passenger. • The shift lever ...

  • Page 38: Foot Brake Pedal

    OPERATING ELEMENTS 100212-10 Foot brake pedal 5.33 100232-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. The footbrake pedal  is located in front of the right footrest. ...

  • Page 39: Side Stand

    OPERATING ELEMENTS Side stand 5.34 100233-10 The side stand  is coupled with the safety electric starter system - see the riding instruc-  tions. Possible states Side stand folded out – The vehicle can be supported on the side stand. The safety •...

  • Page 40: General Tips And Hints On Putting Into Operation

    Risk of injury Risk of injury by missing/inadequate protective clothing. – Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the motorcycle. Always wear protective clothing, which must be in perfect condition and meet legal requirements.
  • Page 41 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 42: Running In The Engine

    Warning Danger of accidents Unstable riding behavior. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage. Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack.
  • Page 43 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 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 following traffic, especially in the dark. Check the way your baggage is fixed regularly.

  • Page 44: Riding Instructions

    7 R IDING INSTRUCTIONS Checks before putting into operation Info Make sure that the motorcycle is in a perfect technical condition before use. In the interests of riding safety, make a habit of making a general check before you ride. –...

  • Page 45: Starting

    RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are poisonous and can 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 a closed 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 46 Press the starter for a maximum of 5 seconds. Wait for at least 5 seconds until trying again. This motorcycle is equipped with a safety electric starter system. The engine can be started only if the gearbox is in neutral or the clutch lever is pulled. If you shift into gear when the side stand is folded out and then release the clutch lever, the engine stalls.

  • Page 47: Starting Up

    RIDING INSTRUCTIONS Starting up – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully. Shifting, riding Warning Danger of accidents An abrupt load alterations can cause the vehicle to get out of control. –...
  • Page 48 Warning Danger of accidents Unstable riding behavior. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage. Warning Danger of accidents Unstable handling characteristics due to slipped baggage.
  • Page 49 If you continue with the coolant temperature warning lamp alight, you may have engine failure. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. 100212-10 –...

  • Page 50: Braking

    Danger of accidents Reduced braking caused by spongy pressure point of front or rear brake. – Have the brake system checked in an authorized KTM workshop, and do not ride any further. – For example, if the engine stalls at a junction, just pull the clutch and press the electric starter button.

  • Page 51: Stopping, Parking

    RIDING INSTRUCTIONS Warning Danger of accidents Brake system failure. – If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take your foot off the foot brake pedal if you do not want to brake. Warning Danger of accidents Longer stopping distance due to higher overall weight.
  • Page 52 – The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over.

  • Page 53: Refueling

    Do not allow fuel to get into the ground water, the ground, or the sewage system. Info This motorcycle is equipped with a regulated catalyst. Leaded fuel will destroy the catalyst. You should therefore use unleaded fuel only. and turning it to the position  .
  • Page 54 RIDING INSTRUCTIONS 400405-10 100240-10 – switch off engine. – Open the filler cap. ( P. 33) – Fill the fuel tank with fuel up to measurement  Specification Measurement of   Fuel tank content 12 l (3.2 US gal) – Close the filler cap. ( P.

  • Page 55: Greasing And Service Table

    GREASING AND SERVICE TABLE 8 G REASING AND SERVICE TABLE Important maintenance work to be carried out by an authorized KTM workshop. Engine Change engine oil and oil filter, clean oil screens.  Check and adjust valve clearance.  Check engine mounting screws for tightness.
  • Page 56 GREASING AND SERVICE TABLE Attachments Check the functioning of the electrical equipment. Check screws and nuts for tightness. Brakes Check the front brake linings. ( Check the rear brake linings. ( Check the brake discs. ( Check the front brake brake fluid level. ( Check the rear brake fluid level.

  • Page 57: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop. (As Additional Order)

    K100A: every 10,000 km (6,214 mi) J1A: annually J2A: every 2 years Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) Carry out a complete fork service.  Carry out a complete shock absorber service. ...

  • Page 58: Maintenance Work On Chassis And Engine

    Danger of damage Danger of damage by the vehicle running away or falling over. – Always place the vehicle on a firm and even surface. – Remove the motorcycle from the work stand and rest it on its side stand. – Remove the work stand. –...

  • Page 59: Fork/Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE Fork/shock absorber 100242-01 Adjusting compression damping of fork Info The hydraulic compression damping determines the fork suspension behavior. 100243-10 The fork and the shock absorber offer many options of adapting the chassis to your riding style and the payload.

  • Page 60: Adjusting Rebound Damping Of Fork

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting rebound damping of fork Info The hydraulic rebound damping determines the fork suspension behavior. 100244-10 – Turn back counterclockwise the number of clicks corresponding to the fork type. Specification Compression damping Comfort Standard Sport full payload Info...

  • Page 61: Compression Damping Of Shock Absorber

    The shock absorber can regulate compression damping in low- and high-speed range separately (Dual Compression Control). The term low and high speed refers to the movement of the shock absorber during compression and not the riding speed of the motorcycle.

  • Page 62: Adjusting High-Speed Compression Damping Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE 100245-10 Adjusting high-speed compression damping of the shock absorber Danger Danger of accidents The shock absorber is under high pressure. – The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any mainte- nance on it yourself.
  • Page 63 MAINTENANCE WORK ON CHASSIS AND ENGINE Info The high-speed setting can be seen during the fast compression of the shock absorber. 100246-10 – Turn the adjusting screw  clockwise with an open-ended spanner until it stops.  Info Do not loosen nut  ...

  • Page 64: Adjusting Rebound Damping Of The Shock Absorber

    Turn back counterclockwise the number of clicks corresponding to the shock absorber type. Specification Rebound damping Comfort Standard Sport full payload Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping. – Lean the motorcycle on the side stand. 20 clicks 15 clicks 10 clicks 10 clicks...

  • Page 65: Cleaning Dust Boots Of Fork Legs

    Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. Info Carry out this action on both fork legs. – Jack up the motorcycle. ( P. 56) – Loosen the fork protection. ( P. 64) –...

  • Page 66: Loosening The Fork Protection

    100292-11 – Remove excess oil. – Position the fork protection. ( P. 64) – Remove the motorcycle from the work stand. ( – Remove screws  and take off clamp.  – Remove screws  on left fork leg. Push the fork protection downwards.

  • Page 67: Checking Play Of Steering Head Bearing

    Danger of accidents Unsafe riding behavior due to incorrect steering head bearing play. – The steering head bearing play should be adjusted immediately in an authorized KTM workshop. Info If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time.

  • Page 68: Adjusting Play Of Steering Head Bearing

    Screw, top triple clamp – Mount and tighten screw   Specification Screw, steering stem – Check play of steering head bearing.  – Remove the motorcycle from the work stand. ( M20x1.5 10 Nm (7.4 lbf ft) 17 Nm (12.5 lbf ft) 20 Nm Loctite ® 243™ (14.8 lbf ft) P.

  • Page 69: Adjusting The Handlebar Angle

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the handlebar angle  9.16 100279-10 Handlebar position 9.17 0 0 A 0 0 B 400271-11 – Loosen screw   – Move the handlebar to the desired position and slightly tichten the screws. – Move the handlebar carefully in both directions as far as it will go.

  • Page 70: Adjusting Handlebar Position

    . Remove the handlebar clamp. Remove the handlebar and  lay it to one side. Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines. – Remove the two screws  . Remove the handlebar support.

  • Page 71: Checking Chain Dirt

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking chain dirt 9.19 – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( P. 69) Cleaning the chain 9.20 Warning Danger of accidents Oil or grease on the tires reduces their grip. –...

  • Page 72: Checking The Chain Tension

    MAINTENANCE WORK ON CHASSIS AND ENGINE – After drying, apply chain spray. Offroad chain spray ( P. 170) Checking the chain tension 9.21 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load.

  • Page 73: Adjusting Chain Tension

    On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if necessary. – Lean the motorcycle on the side stand. – Shift gear to neutral.
  • Page 74 MAINTENANCE WORK ON CHASSIS AND ENGINE 100250-10 – Lean the motorcycle on the side stand. – Shift gear to neutral. – Loosen nut   – Loosen nuts   – Adjust the chain tension by turning the adjusting screws  Specification Chain tension Turn the adjusting screws ...

  • Page 75: Checking Rear Sprocket / Engine Sprocket For Wear

    The engine sprocket, rear sprocket and chain should always be replaced together. For safety reasons, the chain has no chain joint. Always have the chain replaced in an authorized KTM workshop, where the necessary chain rivet tool is available. –...

  • Page 76: Checking Chain Wear

    New chains wear out faster on old, worn sprockets. For safety reasons, the chain has no chain joint. Always have the chain changed in an authorized KTM workshop, where the necessary tool is available.  15 kg (33 lb.)

  • Page 77: Adjusting Chain Guide

    100299-10 Checking brake discs 9.26 Warning Danger of accidents Reduced braking due to worn brake discs. – Worn brake discs should be replaced immediately in an authorized KTM workshop. – Remove screws  and  . Take off the chain guide.  ...

  • Page 78: Checking Free Play Of Hand Brake Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE 400406-10 Checking free play of hand brake lever 9.27 Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake in the brake system. The front brake can fail due to overheating.

  • Page 79: Adjusting Free Travel Of Handbrake Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE 100251-10 Adjusting free travel of handbrake lever 9.28 100252-10 – Push the hand brake to the handlebar and check free play  Free play of hand brake lever » If the free travel does not meet specifications: –...

  • Page 80: Checking Front Brake Fluid Level

    Have the brake system checked in an authorized KTM workshop, and do not ride any further. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. 100253-10 Adding brake fluid for front brake  9.30 Warning Danger of accidents Brake system failure.
  • Page 81 If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –...

  • Page 82: Brake Linings

    100254-10 Brake linings 9.31 The brake linings fitted by KTM were tested over long periods and ensure optimal braking properties. The type names of brake pads are entered in the homologation documents. Info 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 linings.

  • Page 83: Checking The Front Brake Linings

    Changing the front brake linings  9.33 Warning Danger of accidents Improper brake maintenance and repair. – Always have your brake system maintained and repaired in an authorized KTM workshop. – Check the brake linings for minimum thickness  Minimum thickness   »...
  • Page 84 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 85 MAINTENANCE WORK ON CHASSIS AND ENGINE 100254-11 100290-10 – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws   – Remove the cover  with membrane   – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons.
  • Page 86 MAINTENANCE WORK ON CHASSIS AND ENGINE 400418-10 100291-01 100254-12 – Check that leaf spring  in the brake caliper and sliding plate   support are seated correctly. – Insert the brake pads, insert the bolt and mount the split pin. – Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot.

  • Page 87: Checking Free Play Of Foot Brake Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking free play of foot brake lever 9.34 Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can fail due to overheating.

  • Page 88: Checking Rear Brake Fluid Level

    – MINIf the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further. –...

  • Page 89: Topping Up Brake Fluid Of Rear Brake

    MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. 100258-10 Topping up brake fluid of rear brake  9.37 Warning Danger of accidents Brake system failure.
  • Page 90 MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –...

  • Page 91: Checking The Rear Brake Linings

    100260-10 Changing rear brake linings  9.39 Warning Danger of accidents Improper brake maintenance and repair. – Always have your brake system maintained and repaired in an authorized KTM workshop. – Check the brake linings for minimum thickness  Minimum thickness   »...
  • Page 92 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 93 MAINTENANCE WORK ON CHASSIS AND ENGINE 100259-10 100288-10 400419-10 – Stand the vehicle upright. – Remove screw cover  with membrane   – Press the brake caliper by hand on to the brake disc in order to press back the brake piston.

  • Page 94: Removing Front Wheel

    Refit screw with membrane. Info Clean up overflowed or spilt brake fluid immediately with water. – Jack up the motorcycle. ( P. 56) – Press the brake caliper by hand on to the brake disc in order to press back the brake...
  • Page 95 MAINTENANCE WORK ON CHASSIS AND ENGINE 100262-10 100263-10 100264-10 – Remove screw   – Loosen screw   – 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.

  • Page 96: Fitting Front Wheel

    Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc. – Remove the motorcycle from the work stand. ( – Pull the front wheel brake and push down hard on the fork several times to align the fork legs.

  • Page 97: Removing Rear Wheel

    – Fully tighten screw   Specification Screw, fork stub – Jack up the motorcycle. ( P. 56) – Press the brake caliper by hand on to the brake disc in order to press back the brake piston. – Remove nut ...

  • Page 98: Fitting Rear Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE Fitting rear wheel  9.43 Warning Danger of accidents Reduced braking 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 99: Checking The Rear Hub Rubber Dampers

    Nut, rear wheel spindle – Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot. – Remove the motorcycle from the work stand. ( – Remove the rear wheel.  P. 95) ...

  • Page 100: Tire Condition Checking

    MAINTENANCE WORK ON CHASSIS AND ENGINE 100271-10 100272-10 Tire condition checking 9.45 Warning Danger of accidents Uncontrollable handling behavior caused by a flat tire. – For your own safety, have damaged tires changed immediately. – Check rubber dampers  of the rear hub for damage and wear. ...
  • Page 101 Info The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle. Worn tires have a negative effect on riding behavior, especially on wet surfaces. 100273-01 –...

  • Page 102: Checking Tire Air Pressure

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking tire air pressure 9.46 Info Low tire air pressure leads to abnormal wear and overheating of the tire. Correct tire air pressure ensures optimal riding comfort and maximum tire service life. 100274-01 – Check the depth of the tread.

  • Page 103: Checking Spoke Tension

    Danger of accidents Unstable riding behavior due to loose spokes. – If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop. Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.

  • Page 104: Removing The Seat

    MAINTENANCE WORK ON CHASSIS AND ENGINE 100275-01 Removing the seat 9.48 100230-10 – To check spoke tension, tap each spoke with a screwdriver. Specification You should hear a high note. Spoke nipple, front wheel Spoke nipple, rear wheel Info If you hear different tone frequencies from different spokes, this is an indication of different spoke tensions.

  • Page 105: Mounting The Seat

    MAINTENANCE WORK ON CHASSIS AND ENGINE Mounting the seat 9.49 100276-10 Removing the battery  9.50 Warning Risk of injury Battery acid and battery gases cause serious cauterization. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. –...

  • Page 106: Installing The Battery

    Press the wiring harness to one side and pull the battery out of the battery rack. Info Never operate the motorcycle with a discharged battery or without a battery. In both cases, electrical components can safety equipment can be damaged. The vehicle is then no longer safe to ride.

  • Page 107: Recharging The Battery

    MAINTENANCE WORK ON CHASSIS AND ENGINE Recharging the battery  9.52 Warning Risk of injury Battery acid and battery gases cause serious cauterization. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...
  • Page 108 MAINTENANCE WORK ON CHASSIS AND ENGINE Info Even if there is no load on the battery, it loses power every day. The charge state and the type of charge are very important for the service life of the battery. Fast recharging with a high charge current shortens the battery's service life. If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes.

  • Page 109: Changing The Main Fuse

    After charging, switch off and disconnect the battery charger. Specification The charge current, charge voltage and charge time must not be exceeded. Charge the battery regularly when the motorcycle is not in use. – Install the battery.  P. 104) on the battery casing.
  • Page 110 A reserve fuse  is located in the starter relay.  – Fit a new main fuse. Fuse (58011109130) ( P. 158) Info If the new fuse burns out, contact an authorized KTM workshop. – Check the functioning of the electrical equipment.

  • Page 111: Changing Fuses Of Individual Power Consumers

    MAINTENANCE WORK ON CHASSIS AND ENGINE Changing fuses of individual power consumers 9.54 Info The fuse box containing the fuses of individual power consumers is located under the seat. 600604-11 – Attach the protection covers. – Mount the seat. ( P.
  • Page 112 MAINTENANCE WORK ON CHASSIS AND ENGINE 600606-10 – Remove defective fuse. Specification Fuse 1 - 10A - ignition, combination instrument, alarm system (optional) Fuse 2 - 10A - clock, ignition (EFI control unit) Fuse 3 - 10A - throttle valve control unit Fuse 4 - 10A - fuel pump Fuse 5 - 10A - radiator fan Fuse 6 - 10A - horn, brake light, flasher light, alarm system (optional) Fuse 7 - 15A - high beam, low beam, parking light, tail light, license plate lamp...

  • Page 113: Adjusting The Engine Characteristic

    Fuse (75011088015) ( P. 158) Info If the new fuse burns out, contact an authorized KTM workshop. Replace the spare fuse in the fuse box so that it will be available if needed. – Check the functioning of the power consumer.
  • Page 114 MAINTENANCE WORK ON CHASSIS AND ENGINE 100237-10 100238-10 – Pull the Map‑Select switch and holder  – Pull the Map‑Select switch out of the holder. – Turn the adjusting wheel until the desired digit is next to marking  Set the Map‑Select switch to Soft. –...

  • Page 115: Removing Headlight Mask With Headlight

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing headlight mask with headlight 9.56 600607-10 100294-10 – Switch off all power-consuming components and switch off the engine. – Protect the fender against damage by covering it with a cloth. – Remove the screws  on the left and right.

  • Page 116: Refitting The Headlight Mask With The Headlight

    MAINTENANCE WORK ON CHASSIS AND ENGINE Refitting the headlight mask with the headlight 9.57 100294-11 100295-10 – Connect the connectors of headlight  – Check lighting function. – Remove the cloth from the fender, attach the headlight mask to points  and swing it up to the steering head. and flasher lights ...

  • Page 117: Changing The Headlight Bulb

    MAINTENANCE WORK ON CHASSIS AND ENGINE 100296-10 Changing the headlight bulb 9.58 Note Damage to reflector Keep the glass of the bulb free of grease. – Clean the glass bulb with a clean cloth before mounting. Any grease on the glass will evaporate by the heat and be deposited on the reflector.

  • Page 118: Changing The Parking Light Bulb

    MAINTENANCE WORK ON CHASSIS AND ENGINE 600611-10 Changing the parking light bulb 9.59 Note Damage to reflector Keep the glass of the bulb free of grease. – Clean the glass bulb with a clean cloth before mounting. Any grease on the glass will evaporate by the heat and be deposited on the reflector.

  • Page 119: Changing The Flasher Bulb

    MAINTENANCE WORK ON CHASSIS AND ENGINE 600612-10 Changing the flasher bulb 9.60 Note Damage to reflector Keep the glass of the bulb free of grease. – Clean the glass bulb with a clean cloth before mounting. Any grease on the glass will evaporate by the heat and be deposited on the reflector.

  • Page 120: Checking Headlamp Setting

    – Make another mark at a distance of   Specification Distance   – Stand the motorcycle at a distance of  beam. Specification Distance   – Check the headlamp setting. The boundary between light and dark must be exactly on the lower mark for a motor- cycle with driver.

  • Page 121: Adjusting The Headlight Range

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the headlight range 9.62 600613-01 Removing the air filter  9.63 100285-10 – Check the headlamp setting. ( P. 118) – Use a screwdriver (see illustration) to adjust the headlight range. Specification The boundary between light and dark must be exactly on the lower mark for a motor- cycle with a rider (mark is applied under: Checking headlight adjustment).

  • Page 122: Installing The Air Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE 100286-10 Installing the air filter  9.64 100287-10 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.

  • Page 123: Cooling System

    MAINTENANCE WORK ON CHASSIS AND ENGINE 100285-11 Cooling system 9.65 600614-10 – Mount and tighten screws   Specification Remaining screws, chassis – Mount the seat. ( P. 103) The water pump  in the engine forces the coolant to flow.  The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap ...

  • Page 124: Checking The Antifreeze And Coolant Level

    9.66 Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure. – Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cool- ing system to cool down.
  • Page 125 MAINTENANCE WORK ON CHASSIS AND ENGINE 100283-10 Condition Engine is cold. – Stand the motorcycle on its side stand on a horizontal surface. – Remove the cap of the compensating tank  – Check antifreeze of coolant. −25… −45 °C (−13… −49 °F) »...

  • Page 126: Checking The Coolant Level

    9.67 Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure. – Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cool- ing system to cool down.
  • Page 127 Change clothes that have come into contact with coolants. Keep coolants out of the reach of children. 100283-10 Condition Engine is cold. – Stand the motorcycle on its side stand on a horizontal surface. – Check the coolant level in the compensating tank  The coolant level must be within the range shown in the figure. »...

  • Page 128: Draining Coolant

    9.68 Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure. – Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cool- ing system to cool down.

  • Page 129: Filling The Cooling System

     Specification Plug, drain hole of water pump – Install the engine guard. ( P. 132) – Stand the motorcycle on its side stand on a horizontal surface. – Remove radiator cap   M10x1 15 Nm (11.1 lbf ft)
  • Page 130 MAINTENANCE WORK ON CHASSIS AND ENGINE 600619-10 100283-11 – Refill the coolant. Alternative 1 Coolant ( P. 166) Alternative 2 Coolant (mixed ready to use) ( – Fill the radiator completely with coolant. Mount radiator cap  – Remove the cap from compensating tank  figure.

  • Page 131: Adjusting Basic Position Of Clutch Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting basic position of clutch lever 9.70 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 132: Checking Play In Gas Bowden Cable

    MAINTENANCE WORK ON CHASSIS AND ENGINE 100281-10 Checking play in gas Bowden cable 9.72 400192-10 – Remove screws   – Remove the cover  with membrane   – Check the fluid level. Fluid level under top level of container. » If the fluid level does not meet specifications: –...

  • Page 133: Adjusting Play In Gas Bowden Cable

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting play in gas Bowden cable  9.73 100280-10 Danger Danger of poisoning Exhaust gases are poisonous and can 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 a closed space.

  • Page 134: Removing The Engine Guard

    9.74 100198-10 Installing the engine guard 9.75 100199-10 – Stand the motorcycle on its side stand on a horizontal surface. – Remove screws  on the left and right.  – Pull the engine guard forward out of the holders and set it down.

  • Page 135: Checking Engine Oil Level

    Mount the oil filter.  P. 137) – Fill up with engine oil.  P. 139) – Stand the motorcycle upright on a horizontal surface. Condition The engine is at operating temperature. – Check the engine oil level. Info After switching off the engine, wait for one minute and then check.

  • Page 136: Draining Engine Oil

    MAINTENANCE WORK ON CHASSIS AND ENGINE Draining engine oil  9.78 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. – Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 137: Removing The Oil Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE 100201-01 Removing the oil filter  9.79 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. – Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately. Warning Environmental hazard Problem materials cause environmental damage.
  • Page 138 MAINTENANCE WORK ON CHASSIS AND ENGINE 100202-10 100203-10 – Remove screws  . Remove oil filter cover   – Pull the oil filter insert  out of the oil filter casing.  Circlip pliers reverse (51012011000) – Remove screws  . Remove oil filter cover  ...

  • Page 139: Mounting Oil Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE Mounting oil filter  9.80 100204-10 Cleaning oil screens  9.81 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. – Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately. Warning Environmental hazard Problem materials cause environmental damage.
  • Page 140 MAINTENANCE WORK ON CHASSIS AND ENGINE 100205-10 100206-10 100207-10 – Remove the plug  with the oil screen   – Remove the plug  with the oil screen   – Drain the remaining engine oil. – Thoroughly clean parts and sealing area. –...

  • Page 141: Filling Up With Engine Oil

    MAINTENANCE WORK ON CHASSIS AND ENGINE 100208-10 Filling up with engine oil  9.82 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. 100209-10 – Position oil screen  with O-rings.  – Refit plug  with O-ring and tighten it.

  • Page 142: Topping Up Engine Oil

    MAINTENANCE WORK ON CHASSIS AND ENGINE Topping up engine oil 9.83 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. 100209-10 – Remove filler plug with O-ring  from the clutch cover and add engine oil. ...

  • Page 143: Troubleshooting

    P. 109) – Reconnect coupling of fuel hose connec- tion. – Clean socket connector and treat it with contact spray. – Read the error memory with the KTM diagnostics tool and correct the fault. – Have the air filter changed.
  • Page 144 Engine oil too thin (low viscosity) Action – Have the fuel filter changed. – Read the error memory with the KTM diagnostics tool and correct the fault. – Check the cooling system for leakage. – Check the coolant level. ( P.
  • Page 145 TROUBLESHOOTING Faults Headlight and parking light not functioning Flasher light, brake light and horn not functioning Time is not (correctly) displayed Battery discharged Combination instrument shows nothing in the display Speedometer in combination instrument not functioning Possible cause Fuse 7 blown Fuse 6 blown Fuse 2 blown Ignition not switched off when vehicle was...

  • Page 146: Flashing Code

    FLASHING CODE FLASHING CODE Fault Description FI warning lamp (MIL) flashes briefly 2x FI warning lamp (MIL) flashes briefly 6x FI warning lamp (MIL) flashes briefly 8x FI warning lamp (MIL) flashes briefly 9x FI warning lamp (MIL) flashes 1x long, 2x short FI warning lamp (MIL) flashes 1x long, 3x short FI warning lamp (MIL) flashes 1x long, 4x short...
  • Page 147 FLASHING CODE Fault Description FI warning lamp (MIL) flashes 2x long, 7x short FI warning lamp (MIL) flashes 3x long, 3x short FI warning lamp (MIL) flashes 3x long, 7x short FI warning lamp (MIL) flashes 4x long, 1x short FI warning lamp (MIL) flashes 4x long, 5x short FI warning lamp (MIL) flashes 5x long, 4x short...
  • Page 148 FLASHING CODE Fault Description FI warning lamp (MIL) flashes 9x long, 1x short FI warning lamp (MIL) flashes 9x long, 2x short Possible cause Action – Malfunction in CAN bus com- Check CAN bus communica- munication tion.  – Malfunction in voltage supply Check the throttle valve con- circuit of throttle valve control trol unit. ...

  • Page 149: Cleaning

    If you have ridden the vehicle on salted roads, clean it with cold water. Warm water would reinforce the effect of the salt. – After rinsing the motorcycle thoroughly with a soft jet of water, dry it with compressed air and a cloth.
  • Page 150 The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate. – Push back the protection covers on the handlebar instruments to allow water to evaporate. – After the motorcycle has cooled off, oil or grease all moving parts and bearings. – Clean the chain. ( P. 69) –...

  • Page 151: Conservation For Winter Operation

    13.1 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 you have ridden the vehicle on salted roads, clean it with cold water. Warm water would reinforce the effect of the salt.

  • Page 152: Storage

    (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season. – Make sure the tank is as empty as possible so that you can fill up with fresh fuel when you put the motorcycle back into operation. – Clean the motorcycle. ( P.

  • Page 153: Putting Into Operation After Storage

    STORAGE – Cover the motorcycle with a porous sheet or blanket. 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 154: Technical Data - Engine

    TECHNICAL DATA - ENGINE TECHNICAL DATA - ENGINE Design Displacement Stroke Bore Compression ratio Control Valve diameter, intake Valve diameter, exhaust Valve play, cold Crankshaft bearing Conrod bearing Piston pin bearing Pistons Piston rings Engine lubrication Primary transmission Clutch Gearbox Transmission ratio 1st gear 2nd gear...

  • Page 155: Capacity - Engine Oil

    TECHNICAL DATA - ENGINE 6th gear Mixture preparation Ignition Generator Spark plug spark plug electrode gap Cooling Starting aid Capacity - engine oil 15.1 Engine oil 1.70 l (1.8 qt.) Capacity - coolant 15.2 Coolant 1.20 l (1.27 qt.) 23:20 Electronic fuel injection Contactless controlled fully electronic ignition with digital ignition adjustment 12 V, 224 W NGK LKAR 8AI - 9...

  • Page 156: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES TECHNICAL DATA - ENGINE TIGHTENING TORQUES Plug, oil bore Screw, membrane fixation Oil jet, conrod lubrication Hose clamp, intake flange Screw, cover plate for oil return line Screw, breather cover on valve cover Screw, gear sensor Screw, clutch spring Locking screw for bearing Screw, oil filter cover...
  • Page 157 TECHNICAL DATA - ENGINE TIGHTENING TORQUES Screw, engine housing Screw, shift drum locating Screw, shift lever Screw, timing chain tensioning rail Screw, starter motor Screw, stator bracket Screw, thermostat housing Screw, valve cover Screw, water pump cover Screw, water pump wheel Screw, cylinder Screw, cylinder head Plug, vacuum connection...
  • Page 158 TECHNICAL DATA - ENGINE TIGHTENING TORQUES Screw, cylinder head Spark plug Coolant temperature sensor on cylinder head Oil drain plug with magnet Oil pressure regulator valve plug Plug, oil bore Engine case stud Ignition rotor nut Nut, engine sprocket Nut, inner clutch hub Nut, primary gear Plug, oil screen Plug, timing chain tensioner...

  • Page 159: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS TECHNICAL DATA - CHASSIS Frame Fork Shock absorber Suspension travel front Rear Brake system front Rear Diameter of brake discs front Rear Wear limit of brake discs front Rear Tire air pressure, road, solo front Rear Tire air pressure with passenger / fully loaded front Rear...

  • Page 160: Lighting Equipment

    TECHNICAL DATA - CHASSIS Rear wheel gearing Chain Steering head angle Wheelbase Seat height unloaded Ground clearance unloaded Weight without fuel Maximum permissible front axle load Maximum permissible rear axle load Maximum permissible overall weight Battery Fuse Fuse Fuse Lighting equipment 17.1 Headlight Parking light...

  • Page 161: Capacity - Fuel

    TECHNICAL DATA - CHASSIS Brake / tail light Licence plate lamp Front tire 90/90 - 21 54 H TL Metzeler Enduro 3 Sahara For further information, see the Service section under: http://www.ktm.com Capacity - fuel 17.2 Fuel tank content 12 l (3.2 US gal) Fuel reserve W2,1x9,5d Rear tire 140/80 - 18 70 H TL Metzeler Enduro 3 Sahara...

  • Page 162: Technical Data - Fork

    TECHNICAL DATA - FORK TECHNICAL DATA - FORK Fork part number Fork Compression damping Comfort Standard Sport full payload Rebound damping Comfort Standard Sport full payload Spring length with preload spacer(s) Spring rate Weight of rider: 75… 85 kg (165… 187 lb.) Air chamber length Fork length Fork oil (...

  • Page 163: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number Shock absorber Compression damping, high-speed Comfort Standard Sport full payload Compression damping, low-speed Comfort Standard Sport full payload Rebound damping Comfort Standard Sport full payload Spring preload Spring rate Weight of rider: 75…...
  • Page 164 TECHNICAL DATA - SHOCK ABSORBER Fitted length 395 mm (15.55 in)

  • Page 165: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES TECHNICAL DATA - CHASSIS TIGHTENING TORQUES Remaining screws, chassis Spoke nipple, front wheel Spoke nipple, rear wheel Screw, exhaust heat shield Screw, electrical holder Screw, footbrake pedal foothold Screw, fuel pump Screw, fuel level indicator Screw, side cover Screw, headlight mask Screw, side stand switch...
  • Page 166 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES Screw, magnetic holder on side stand Screw, voltage regulator/rectifier Screw, SLS valve Screw, ignition lock Nut, rear sprocket screw Nut, manifold on cylinder head Remaining nuts, chassis Remaining screws, chassis Screw, exhaust clamp on main silencer Screw, front brake caliper Screw, main silencer holder Screw, main silencer holder on fuel tank...
  • Page 167 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES Screw, handlebar clamp Screw, side stand bracket Screw, connection lever on frame Remaining nuts, chassis Remaining screws, chassis Engine carrying screw Screw, top shock absorber Screw, bottom shock absorber Screw, foot brake pedal Screw, handlebar support Screw, engine bearer on frame Screw, side stand Lambda probe...

  • Page 168: Substances

    SUBSTANCES Brake fluid DOT 4 / DOT 5.1 according to – Specification – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Castrol and Motorex Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ® Motorex –...
  • Page 169 – SAE ( P. 171) (SAE 10W/60) Specification – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex Synthetic engine oil Supplier ® Motorex –...
  • Page 170 SUBSTANCES Specification – Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Motorex Supplier ® Motorex – Hydraulic Fluid 75 Super unleaded (ROZ 95 / RON 95 / PON 91) according to –...

  • Page 171: Auxiliary Substances

    AUXILIARY SUBSTANCES AUXILIARY SUBSTANCES Chain cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Cleaning and polishing materials for metal, rubber and plastic Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Protect & Shine 645 Contact spray Specification –...
  • Page 172 Motorcycle cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Moto Clean 900 Offroad chain spray Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Lube 622 Universal oil spray Specification – ® KTM recommends Motorex products. Supplier ® Motorex –...
  • Page 173 Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines. With most motorcycles, the gearbox and the clutch are lubricated with the oil as the engine. The JASO MA Standard meets these special requirements.
  • Page 174 INDEX INDEX Air filter fitting ........120 removing .
  • Page 175 INDEX Setting/resetting TRIP 1 display ....30 Setting/resetting TRIP 2 display ....31 Speed display .
  • Page 176 Maintenance ........8 Motorcycle cleaning .
  • Page 177 INDEX Oil screens cleaning ........137 OWNER'S MANUAL Basics .
  • Page 178 INDEX Technical data Chassis ....... 157-159 Chassis tightening torques ....163-165 Engine .
  • Page 179 *3211239en* 3211239en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com 03/2008 Photo Mitterbauer...

This manual is also suitable for:

690 enduro eu, 690 enduro aus/uk690 enduro eu 2008690 enduro aus/uk 2008

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