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5. 690 Enduro R EU 2013
6. Repair manual

• Page 1
  REPAIR MANUAL 2013 690 Enduro R EU 690 Enduro R AUS/UK 690 Enduro R USA Art. no. 3206150en…
• Page 3
  KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.

• Page 4: Table Of Contents

  TABLE OF CONTENTS Adjusting the rebound damping of the shock TABLE OF CONTENTS MEANS OF REPRESENTATION ……..5 absorber…………38 Symbols used ……….. 5 Measuring the unloaded rear wheel sag ….. 38 Formats used………… 5 Checking the static sag of the shock absorber ..38 SAFETY ADVICE…………

• Page 5
  TABLE OF CONTENTS 13.7.8 Checking the chain, rear sprocket, engine 17.3.9 Removing thermostat …….. 112 sprocket, and chain guide……78 17.3.10 Setting engine to ignition top dead center … 112 13.7.9 Cleaning the chain ……..80 17.3.11 Removing water pump wheel…… 113 13.7.10 Checking the rear hub rubber dampers..
• Page 6
  TABLE OF CONTENTS 17.4.30 Checking the clutch ……..138 20 LUBRICATION SYSTEM……….169 17.4.31 Preassembling the antihopping clutch..140 20.1 Oil circuit…………. 169 17.4.32 Checking shift mechanism……141 20.2 Checking the engine oil level……169 17.4.33 Preassembling shift shaft ……141 20.3 Checking the engine oil pressure ….

• Page 7: Means Of Representation

  MEANS OF REPRESENTATION Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips.

• Page 8: Safety Advice

  Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle. This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available. Safety advice A number of safety instructions need to be followed to operate the vehicle safely.

• Page 9: Important Notes

  Guarantee, 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 & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle.

• Page 10: 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. B01289-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.

• Page 11: Shock Absorber Part Number

  SERIAL NUMBERS Shock absorber part number The shock absorber part number is on the left of the shock absorber. 101048-10…

• Page 12: Motorcycle

  MOTORCYCLE Raising the motorcycle with the lift stand 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 13: Removing The Motorcycle From The Work Stand

  MOTORCYCLE Removing the motorcycle from the work stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Secure the motorcycle against falling over. – Remove the work stand and lean the vehicle on the side stand. 300201-10 –…

• Page 14: Starting The Motorcycle To Make Checks

  MOTORCYCLE Info Do not press the electric starter button until the combination instrument function check is finished. When starting, DO NOT open the throttle. If you open the throttle during the starting procedure, fuel is not injected by the engine management system and the engine cannot start.

• Page 15: Fork, Triple Clamp

  FORK, TRIPLE CLAMP Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn adjusting screws clockwise all the way. Info The adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs.

• Page 16: Cleaning The Dust Boots Of The Fork Legs

  FORK, TRIPLE CLAMP Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 10) – Loosen the fork protection. ( p. 14) Main work – Push dust boot of both fork legs downwards. Info The dust boots remove dust and coarse dirt particles from the inside fork tubes.

• Page 17: Removing The Fork Legs

  FORK, TRIPLE CLAMP Removing the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 10) – Tie down the rear of the vehicle. Main work – Remove screws – Press back the brake linings with a light lateral tilting of the brake caliper on the brake disc.

• Page 18: Installing The Fork Legs

  FORK, TRIPLE CLAMP – Remove screws . Remove the fork protector from above. 202027-10 Installing the fork legs – Slide on the fork protector from above and position it. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 202027-11 –…

• Page 19: Servicing The Fork

  FORK, TRIPLE CLAMP 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 screw and the wheel spindle.

• Page 20: Disassembling The Fork Legs

  FORK, TRIPLE CLAMP 6.10 Disassembling the fork legs Info The steps are identical for both fork legs. Condition The fork legs are disassembled. – Note down the present state of rebound damping and compression damping – Completely open the adjusters of the rebound and compression damping. 201470-10 –…

• Page 21
  FORK, TRIPLE CLAMP – Clamp the special tool in the vise. Loosen screw cover 200647-12 – Remove screw cover with preload spacers – Remove adjusting tube 200648-12 – Pull the spring down. Remove the special tool. – Remove the spring. 200649-01 –…
• Page 22
  FORK, TRIPLE CLAMP – Remove the cartridge. 200653-01 – Remove dust boot 200735-10 – Remove lock ring Info The lock ring has a beveled end where a screwdriver can be applied. 200656-01 – Warm up the outer tube in area of the lower sliding bushings.

• Page 23: Disassembling The Cartridge

  FORK, TRIPLE CLAMP 6.11 Disassembling the cartridge Info The steps are identical for both fork legs. Preparatory work – Disassemble the fork legs. ( p. 18) Main work – Degrease the piston rod. – Clamp the piston rod with the special tool. Clamping stand (T14016S) ( p.

• Page 24: Disassembling The Tap Compression

  FORK, TRIPLE CLAMP – Degrease the piston rod. – Clamp the piston rod with the special tool. Clamping stand (T14016S) ( p. 224) 200697-10 – Remove nut – Remove shim stack completely. 200698-11 – Remove the piston. – Completely remove shim stack 200699-11 –…

• Page 25: Checking The Fork Legs

  FORK, TRIPLE CLAMP Main work – Clamp the tap compression in a bench vise using soft jaws. – Remove nut – Remove the spring. – Remove washer 201482-10 – Remove piston – Remove shim stack 201483-10 – Extract the tap compression. –…

• Page 26: Assembling The Tap Compression

  FORK, TRIPLE CLAMP – Measure the run-out of the inner tube. ≤ 0.20 mm (≤ 0.0079 in) Run-out of inner tube » If the measured value is greater than the specified value: – Replace the inner tube. 200685-10 – Check the outer tube for damage. »…

• Page 27: Assembling The Cartridge

  FORK, TRIPLE CLAMP – Clamp the tap compression in a bench vise using soft jaws. – Mount shim stack Info Mount the smaller shims below. – Mount pistons with O-ring. Info The side with the largest inside diameter faces upward. 201485-10 –…

• Page 28
  FORK, TRIPLE CLAMP – Mount piston with the piston ring. Info The side with the largest inside diameter faces downward. – Mount shim stack Info Align the triangular plate exactly with the piston opening. – Mount and tighten nut Guideline Tap rebound nut M6x0.5 5 Nm (3.7 lbf ft)

• Page 29: Assembling The Fork Legs

  FORK, TRIPLE CLAMP – Screw on fluid barrier as far as it will go. Info The fluid barrier must be tightened as much as possible. Do not use tools. 200746-12 6.16 Assembling the fork legs Info The steps are identical for both fork legs. Preparatory work –…

• Page 30
  FORK, TRIPLE CLAMP – Push on the lower sliding bushing – Mount the upper sliding bushing Info Without using a tool, carefully pull the stack apart by hand. 200671-10 – Heat up the outer tube in area of the lower sliding bushings. Guideline 50 °C (122 °F) –…
• Page 31
  FORK, TRIPLE CLAMP Info The special tool must be used to prevent the adjusting tube from being lifted and thus to prevent oil from reaching the piston rod. – Lubricate the O-ring. Lubricant (T158) ( p. 212) – Mount and tighten compression adjuster Guideline Compression adjuster M14x1…
• Page 32
  FORK, TRIPLE CLAMP – Clamp the special tool in the vise. – Grease the thread of the piston rod. Lubricant (T159) ( p. 212) – Grease the upper edge of the piston rod. Lubricant (T158) ( p. 212) – Screw the screw cover with the preload spacers on to the piston rod. Info 201477-10 The screw cover must be screwed to the stop before the piston rod starts…

• Page 33: Checking The Steering Head Bearing Play

  FORK, TRIPLE CLAMP Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seri- ously alter the vehicle’s ride behavior. – Extreme modifications to the adjustment of the suspension compo- nents can cause a serious deterioration in the handling characteris- tics and overload some components.

• Page 34
  FORK, TRIPLE CLAMP Guideline Screw, steering stem 20 Nm (14.8 lbf ft) Finishing work – Check the steering head bearing play. ( p. 31) – Remove the motorcycle from the lift stand. ( p. 10)

• Page 35: Handlebar, Controls

  HANDLEBAR, CONTROLS Handlebar position 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 36: Checking The Play In The Throttle Cable

  33) Main work – Move the handlebar to the straight-ahead position. – Use the KTM diagnostics tool to set the throttle stepper motor to the neutral posi- tion. – Loosen lock nut – Set the play in the throttle cable by turning adjusting screw…

• Page 37
  HANDLEBAR, CONTROLS – Tighten lock nut…

• Page 38: Frame

  FRAME Removing the engine guard – Remove screws on the left and right. – Pull the engine guard forward out of the holders and set it down. 202021-10 Installing the engine guard – Slide the engine guard into holders at the rear. –…

• Page 39: Shock Absorber, Swingarm

  SHOCK ABSORBER, SWINGARM 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. Info The high-speed setting takes effect during the fast compression of the shock absorber. –…

• Page 40: Adjusting The Rebound Damping Of The Shock Absorber

  SHOCK ABSORBER, SWINGARM 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. – Turn adjusting screw clockwise up to the last perceptible click.

• Page 41: Checking The Riding Sag Of The Shock Absorber

  SHOCK ABSORBER, SWINGARM Checking the riding sag of the shock absorber – Measure distance of rear wheel unloaded. ( p. 38) – With another person holding the motorcycle, the rider, wearing full protective cloth- ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up 0 0 A and down a few times.

• Page 42: Adjusting The Riding Sag

  SHOCK ABSORBER, SWINGARM Adjusting the riding sag Preparatory work – Raise the motorcycle with the work stand. ( p. 10) – Remove the seat. ( p. 62) – Take off the side cover. ( p. 63) – Remove the shock absorber. ( p.

• Page 43: Installing The Shock Absorber

  SHOCK ABSORBER, SWINGARM – Remove screw – Repeat the operation on the opposite side. 202043-10 – Loosen screw – Remove screw – Remove screw 202044-10 – Swing the rear end upwards. – Lift shock absorber upwards and remove. 202045-11 9.10 Installing the shock absorber Main work –…

• Page 44: Servicing The Shock Absorber

  SHOCK ABSORBER, SWINGARM – Lift the rear fairing. – Mount and tighten screws Guideline Screw, main silencer holder on fuel 25 Nm tank (18.4 lbf ft) 202037-13 – Mount and tighten screws Guideline Screw, side cover 5 Nm (3.7 lbf ft) 202036-13 Finishing work –…

• Page 45: Removing The Spring

  SHOCK ABSORBER, SWINGARM 9.12 Removing the spring Condition The shock absorber has been removed. – Clamp the shock absorber in the vise using soft jaws for protection. – Measure and note spring length in preloaded state. – Loosen retaining ring and the adjusting ring with the special tool.

• Page 46: Disassembling The Piston Rod

  SHOCK ABSORBER, SWINGARM – Remove screw . Drain the oil. 201277-10 – Remove the piston rod. Drain the remaining oil. 201278-10 – Remove compression adjuster . Remove the spring, sleeve, and piston. 201279-10 9.14 Disassembling the piston rod Preparatory work –…

• Page 47: Checking The Damper

  SHOCK ABSORBER, SWINGARM – Remove supporting plate and rebound shim stack together with piston Info Thread the rebound shim set on a screwdriver and set the parts down together. 300541-10 – Remove compression shim stack with supporting plate Info Thread the compression shim stack on a screwdriver and set the parts down together.

• Page 48: Removing The Heim Joint

  SHOCK ABSORBER, SWINGARM – Measure the diameter of the piston rod. Piston rod ≥ 17.95 mm (≥ 0.7067 in) Diameter » If the specification is not reached: – Change the piston rod. – Measure the run-out of the piston rod. Piston rod 300554-10 ≤…

• Page 49: Installing The Heim Joint

  SHOCK ABSORBER, SWINGARM – Remove lock rings on both sides. 200579-10 – Place special tool underneath and press out the heim joint with special tool Pressing tool (T1207S) ( p. 223) 200580-10 9.17 Installing the heim joint – Place special tool underneath and press in the heim joint as far as the center using special tool Pressing tool (T1206) (…

• Page 50: Assembling The Piston Rod

  SHOCK ABSORBER, SWINGARM 9.18 Assembling the piston rod Preparatory work – Check the damper. ( p. 45) Main work – Clamp the piston rod with the heim joint in a vise. Guideline Use soft jaws. – Mount rubber buffer and locking cap 300543-11 –…

• Page 51: Assembling The Damper

  SHOCK ABSORBER, SWINGARM – Mount and tighten nut Guideline Piston rod nut M12x1 40 Nm (29.5 lbf ft) 300540-11 9.19 Assembling the damper Preparatory work – Check the damper. ( p. 45) – Assemble the piston rod. ( p. 48) Main work –…

• Page 52
  SHOCK ABSORBER, SWINGARM – Grease O-ring of the seal ring retainer. Lubricant (T158) ( p. 212) – Mount the piston rod carefully. 201278-11 – Install the seal ring bearer and push it under the ring groove. – Mount lock ring Info Do not scratch the inner surface.

• Page 53: Bleeding And Filling The Damper

  SHOCK ABSORBER, SWINGARM Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seri- ously alter the vehicle’s ride behavior. – Extreme modifications to the adjustment of the suspension compo- nents can cause a serious deterioration in the handling characteris- tics and overload some components.

• Page 54
  SHOCK ABSORBER, SWINGARM – Measure distance between the floating piston and reservoir hole with the special tool. Depth micrometer (T107S) ( p. 223) The floating piston is positioned all the way at the bottom. 201285-10 – When the vacuum pressure gauge reaches the specified value, turn the Oil reser- voir control lever to Equalize pressure.

• Page 55: Filling The Damper With Nitrogen

  SHOCK ABSORBER, SWINGARM – When the pressure gauge reaches the specified value, turn the Damper control lever to Pressure. Guideline 0 bar Oil is pumped into the damper. The pressure gauge rises to the specified value. 3 bar 200268-10 – When the pressure gauge reaches the specified value, turn the Damper control lever to Vacuum.

• Page 56: Installing The Spring

  SHOCK ABSORBER, SWINGARM – Clamp special tool in the vise. Nitrogen filling tool (T170S1) ( p. 226) – Connect the special tool to the pressure regulator of the filling cylinder. Filling gas — nitrogen – Adjust pressure regulator. Guideline Gas pressure 10 bar (145 psi) 201281-10 –…

• Page 57
  SHOCK ABSORBER, SWINGARM Alternative 2 Warning Danger of accidents Modifications to the suspension settings can seri- ously alter the vehicle’s ride behavior. – Extreme modifications to the adjustment of the suspension compo- nents can cause a serious deterioration in the handling characteris- tics and overload some components.

• Page 58: Exhaust

  EXHAUST 10.1 Removing the manifold Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. Preparatory work – Remove the seat. ( p. 62) –…

• Page 59: Removing The Main Silencer

  EXHAUST – Position the exhaust clamp. – Tighten screw Guideline Screw, main silencer 12 Nm Copper paste clamp (8.9 lbf ft) 202034-11 – Plug in connector of the lambda sensor. Position the cable and secure it with cable binder 202035-10 –…

• Page 60: Installing The Main Silencer

  EXHAUST – Remove screws – Lift the rear fairing. 202036-10 – Remove screws – Remove the main silencer. 202037-10 10.4 Installing the main silencer – Position the main silencer. – Mount and tighten screws Guideline Screw, main silencer holder 25 Nm (18.4 lbf ft) 202037-11 –…

• Page 61: Air Filter

  AIR FILTER 11.1 Removing the air filter Preparatory work – Remove the seat. ( p. 62) Main work – Remove screws . Take off air filter box top 601783-10 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine.

• Page 62: Installing The Air Filter Box

  AIR FILTER Main work – Remove screws – Take off the voltage regulator and hang it to the side in a de-energized state. – Detach and expose hose 202038-10 – Remove screws 202039-10 – Remove screws 202040-10 – Loosen hose clip 202041-10 –…

• Page 63
  AIR FILTER – Position the air filter box. – Mount and tighten hose clip 202041-11 – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 202040-10 – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 202039-11 –…

• Page 64: Fuel Tank, Seat, Trim

  FUEL TANK, SEAT, TRIM 12.1 Opening the filler cap 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 65: Mounting The Seat

  FUEL TANK, SEAT, TRIM 12.4 Mounting the seat 601782-10 – Hook slot of the seat onto screw , press the rear downward and at the same time push it forward. – Push locking pin into lock housing and push the back of the seat down until the locking pin locks in place with an audible click.

• Page 66: Checking The Fuel Pressure

  FUEL TANK, SEAT, TRIM 12.7 Checking the fuel pressure 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 67: Changing The Fuel Filter

  FUEL TANK, SEAT, TRIM – Check the fuel pressure with the filler cap open. Fuel pressure When the fuel pump is active 3.3… 3.7 bar (48… 54 psi) » If the specification is not reached: – Check that the fuel line is clear. –…

• Page 68
  FUEL TANK, SEAT, TRIM – Remove screw on both sides. – Swing the rear end upwards and secure it. 202043-10 – Remove screws and the splash protector. 202046-10 – Remove screws – Pull out the fuel pump. 202047-10 – Disconnect both fuel hose connections –…
• Page 69
  FUEL TANK, SEAT, TRIM – Change fuel screen – Mount the fuel pump housing. 202051-10 – Connect both fuel hose connections – Attach connector 202048-10 – Position the fuel pump. – Mount and tighten screws Guideline Screw, fuel pump 4 Nm (3 lbf ft) 202047-10 –…

• Page 70: Changing The Fuel Pump

  FUEL TANK, SEAT, TRIM – Mount and tighten screws Guideline Screw, side cover 5 Nm (3.7 lbf ft) 202036-12 Finishing work – Disconnect the battery. ( p. 83) – Mount the seat. ( p. 63) – Set the clock. ( p.

• Page 71
  FUEL TANK, SEAT, TRIM – Remove screw on both sides. – Swing the rear end upward and secure it. 202043-10 – Remove screws and the splash protector. 202046-10 – Remove screws – Pull out the fuel pump. 202047-10 – Disconnect both fuel hose connections –…
• Page 72
  FUEL TANK, SEAT, TRIM – Position the rear end. – Mount and tighten screw on both sides. Guideline Screw, fuel tank, bottom 25 Nm Loctite ® 243™ (18.4 lbf ft) 202043-10 – Lift the rear fairing. – Mount and tighten screws Guideline Screw, main silencer holder on fuel 25 Nm…

• Page 73: Wheels

  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 74: Checking The Brake Discs

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

• Page 75: Checking The Rim Run-Out

  WHEELS 13.5 Checking the rim run-out Warning Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time. If the spokes are too tight, they can break due to local overload.

• Page 76: Installing The Front Wheel

  WHEELS – 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 dam- aged.

• Page 77: Installing The Brake Disc Of The Front Brake

  WHEELS Main work – Remove screws . Take off the brake disc. 202087-10 13.6.4 Installing the brake disc of the front brake Main work – Clean the contact surface of the brake disc. – Position the brake disc with the label facing outward. Mount and tighten screws Guideline Screw, front brake disc 14 Nm…

• Page 78: Removing The Brake Disc Of The Rear Brake

  WHEELS Warning Danger of accidents No braking effect when operating the rear brake. – After installing the rear wheel, always operate the foot brake until the pressure point is reached. Main work – Check the rear hub rubber dampers. ( p. 80) –…

• Page 79: Installing The Brake Disc Of The Rear Brake

  WHEELS 13.7.4 Installing the brake disc of the rear brake Main work – Clean the contact surface of the brake disc. – Position the brake disc with the label facing outward. Mount and tighten screws Guideline Screw, rear brake disc 14 Nm Loctite ®…

• Page 80: Adjusting Chain Guide

  WHEELS 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 chain adjusters are in the same position relative to the reference marks…

• Page 81
  WHEELS – 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 different chain positions.

• Page 82: Cleaning The Chain

  WHEELS – Check the chain guide for wear. Info Wear is visible on the front of the chain guide. » If the light part of the chain guide is worn: – Change the chain guide. 400985-01 – Check that the chain guide is firmly seated. »…

• Page 83
  WHEELS 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 84: Wiring Harness, Battery

  WIRING HARNESS, BATTERY 14.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –…

• Page 85: Connecting The Battery

  – Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

• Page 86: Checking The Charging Voltage

  WIRING HARNESS, BATTERY 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 battery, and to test the alternator. With this device, you cannot overcharge the bat- tery.

• Page 87: Changing The Main Fuse

  WIRING HARNESS, BATTERY 14.7 Changing the main fuse 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. Preparatory work –…

• Page 88: Adjusting The Engine Characteristic

  WIRING HARNESS, BATTERY – 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 — EPT control unit Fuse 4 — 10 A — fuel pump Fuse 5 — 10 A — radiator fan Fuse 6 — 10 A — horn, brake light, turn signal Fuse 7 — 15 A — high beam, low beam, parking light, tail light, license plate lamp…

• Page 89
  WIRING HARNESS, BATTERY – 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 90: Brake System

  Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

• Page 91
  BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Press the brake caliper by hand onto the brake disc in order to retract the brake pistons.

• Page 92: Checking The Free Travel Of The Hand Brake Lever

  BRAKE SYSTEM 15.3 Checking the free travel of the hand brake lever 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 circuit. The front brake can fail due to overheating.

• Page 93: Adding Front Brake Fluid

  BRAKE SYSTEM 15.6 Adding front brake fluid Warning Danger of accidents Failure of the brake system. – 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. Warning Skin irritation Brake fluid can cause skin irritation on contact.

• Page 94
  BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Cover the painted parts. – Remove screws – Remove cover with membrane. – Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid.

• Page 95: Checking The Rear Brake Linings

  Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

• Page 96: Checking The Free Travel Of Foot Brake Lever

  BRAKE SYSTEM – Stand the vehicle upright. – Remove screw cap with membrane – Press the brake caliper by hand onto the brake disc in order to retract the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does.

• Page 97: Adjusting The Basic Position Of The Foot Brake Lever

  BRAKE SYSTEM 15.11 Adjusting the basic position of the foot brake lever 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 overheating.

• Page 98: Adding Rear Brake Fluid

  BRAKE SYSTEM 15.13 Adding rear brake fluid Warning Danger of accidents Failure of the brake system. – 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. Warning Skin irritation Brake fluid can cause skin irritation on contact.

• Page 99
  BRAKE SYSTEM – Cover the painted parts. – Take off screw cap with the washer and membrane. – Draw the old brake fluid out of the brake fluid reservoir using a syringe and fill with fresh brake fluid. Bleed syringe (50329050000) ( p.

• Page 100: Lighting System, Instruments

  LIGHTING SYSTEM, INSTRUMENTS 16.1 Combination instrument 16.1.1 Setting kilometers or miles Info If you change the unit, the value is retained and converted accordingly. Making the setting according to the country. Condition The motorcycle is stationary. – Switch on the ignition by turning the ignition key to position ON –…

• Page 101: Setting The Wheel Circumference

  LIGHTING SYSTEM, INSTRUMENTS – Switch on the ignition by turning the ignition key to position ON – Press the MODE button repeatedly until the TRIP 2 mode is active. – Keep the SET button pressed. The TRIP 2 display is set to 0.0. 400841-01 16.1.5 Setting the wheel circumference…

• Page 102: Checking The Headlight Setting

  LIGHTING SYSTEM, INSTRUMENTS 16.2 Checking the headlight setting – 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. – Make another mark at a distance under the first mark.

• Page 103: Installing The Headlight Mask With The Headlight

  LIGHTING SYSTEM, INSTRUMENTS 16.5 Installing the headlight mask with the headlight Main work – Connect the connectors of headlight and turn signal lights – Check lighting function. 601794-11 – Remove the cloth from the fender and position the headlight mask. Holding lugs reach into the headlight mask.

• Page 104: Changing The Headlight Bulb

  LIGHTING SYSTEM, INSTRUMENTS – Pull bulb socket out of the reflector. – Pull parking light bulb out of the bulb socket. – Insert a new parking light bulb in the bulb socket. Parking light (W5W / socket W2.1×9.5d) ( p. 181) –…

• Page 105
  LIGHTING SYSTEM, INSTRUMENTS Main work (690 Enduro R EU/AUS/UK) – Remove the screw on the rear of the turn signal housing. – Tilt headlamp diffuser forward carefully and take it off. – Lightly squeeze the orange plug in the area of the holding lugs and take it off.

• Page 106: Engine

  ENGINE 17.1 Removing the engine Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. ( p. 62) – Disconnect the battery. ( p. 82) – Raise the motorcycle with the work stand. ( p.

• Page 107
  ENGINE – Take off the engine sprocket. – Remove screws – Remove cable binders – Take off the clutch slave cylinder with the gasket and hang it to the side. Info Do not kink the clutch line. Do not activate the clutch lever if the clutch slave cylinder has been removed.

• Page 108: Installing The Engine

  ENGINE – Detach connector of the oil pressure sensor. Remove screw – Release connection . Remove the line with the oil pressure sensor. 202078-10 – Remove screws . Remove the engine bearer. 202077-10 – Position the floor jack under the engine and fix it using the special tool. Floor jack attachment (75029055000) ( p.

• Page 109
  ENGINE Main work – Position the engine in the frame. 202081-10 – Mount swingarm pivot – Mount the screw of the swingarm pivot but do not tighten yet. – Mount screw connection of the lower engine attachment but do not tighten yet. 202080-11 –…
• Page 110
  ENGINE – Position the hoses of the engine breather, the SLS and the oil return line. Mount the spring band clamp using the special tool. Pliers for spring band clamp (60029057100) ( p. 217) 202076-11 – Attach the spark plug connector. –…
• Page 111
  ENGINE – Mount the engine sprocket with the chain. – Position the new lock washer and mount nut but do not tighten yet. – Position the rear wheel. – Mount the chain adjuster and nut. – Push the rear wheel forward so that the chain adjusters are on the tensioning screws, and tighten the nut Guideline Nut, rear wheel spindle…

• Page 112: Engine Disassembly

  Remove the motorcycle from the work stand. ( p. 11) – Take a short test ride. – Read out the fault memory using the KTM diagnostics tool. – Check the engine for leakage. – Check the engine oil level. ( p.

• Page 113: Removing Starter Motor

  ENGINE 17.3.3 Removing starter motor – Remove screws . Take off the starter motor. 300001-01 17.3.4 Removing valve cover – Remove screws . Take off the valve cover with the valve cover seal. 300003-10 17.3.5 Removing the alternator cover – Remove screws .

• Page 114: Removing Oil Filter

  ENGINE – Remove O-ring – Remove contact pin and the contact springs 300007-10 17.3.8 Removing oil filter – Remove screws. Remove the oil filter cover with the O-ring. – Pull oil filter out of the oil filter housing. Circlip pliers reverse (51012011000) ( p.

• Page 115: Removing Water Pump Wheel

  ENGINE – Remove screw Info Look through the hole to check that the position hole of the balancer shaft is visible. – Screw in special tool Engine blocking screw (77329010000) ( p. 222) 300024-10 17.3.11 Removing water pump wheel – Remove screws .

• Page 116: Removing Spacer And Spring

  ENGINE 17.3.13 Removing spacer and spring – Remove the spacer and spring of the shift shaft. 300154-10 17.3.14 Removing spark plug – Remove the spark plug using the special tool Spark plug wrench (75029172000) ( p. 222) 300016-10 17.3.15 Removing timing chain tensioner –…

• Page 117: Removing Cylinder Head

  ENGINE 17.3.17 Removing cylinder head – Remove screws – Alternately loosen screws and remove them. – Take off the cylinder head. 300029-10 17.3.18 Removing piston – Take off the cylinder head gasket – Remove screw – Push the cylinder upward. Info Push the cylinder upward only far enough to allow removal of the piston pin.

• Page 118: Removing Timing Chain Rails

  ENGINE – Install the special tool on the rotor. Hold it tight using the special tool and pull off the rotor by turning the screw in. Extractor (58429009000) ( p. 215) – Remove the special tool. 302120-10 17.3.20 Removing timing chain rails –…

• Page 119: Removing Crankshaft Position Sensor

  ENGINE 17.3.22 Removing crankshaft position sensor – Remove the screws of crankshaft position sensor – Pull cable support sleeve out of the engine case. Take off the crankshaft posi- tion sensor. 300151-10 17.3.23 Removing clutch cage – Clamp the antihopping clutch with special tool Assembly screws (75029033000) ( p.

• Page 120: Removing Primary Gear

  ENGINE – Take off the stepped washer and remove the half-washers – Take off the clutch cage. 302125-10 – Remove needle bearing and supporting plate 300056-10 17.3.24 Removing primary gear – Plug the special tool into the crankshaft. Protection cover (75029090000) ( p.

• Page 121: Removing Shift Shaft

  ENGINE 17.3.26 Removing shift shaft – Push sliding plate away from the shift drum locating . Remove shift shaft with the washer. 300066-10 17.3.27 Removing shift drum locating – Remove screw – Press locking lever away from shift drum locating and take off the shift drum locating.

• Page 122: Removing Left Engine Case

  ENGINE – Remove both oil pump shafts with internal rotors – Take the external rotors out of the engine case. 300072-10 17.3.30 Removing left engine case – Remove screws – Swing the left section of the engine case up and remove the nut or screw of the engine fixing arm.

• Page 123: Removing Transmission Shafts

  ENGINE 17.3.32 Removing transmission shafts – Remove the shift rail 300079-10 – Swing shift forks to one side. – Remove shift drum 300080-10 – Remove shift forks Info Ensure that the pins remain in place. 300081-10 – Remove the lock ring and the stop disk.

• Page 124: Work On Individual Parts

  ENGINE 17.4 Work on individual parts 17.4.1 Work on the right section of the engine case – Remove oil jet – Remove bearing locks of the main shaft bearing , of the countershaft bearing and of the shift drum bearing –…

• Page 125: Work On The Left Section Of The Engine Case

  ENGINE – Mount and tighten the oil jet Guideline Oil nozzle for conrod bear- 2 Nm Loctite ® 243™ ing lubrication (1.5 lbf ft) – Blow compressed air through all oil channels and check that they are clear. – Position the cover plate .

• Page 126
  ENGINE Info When pressing the bearing in, ensure that the engine case section is level to prevent damage. Only press the bearings in via the outer bearing race; otherwise, the bear- ings will be damaged when they are pressed in. –…

• Page 127: Work On The Clutch Cover

  ENGINE 17.4.3 Work on the clutch cover – Remove the shaft seal ring of the crankshaft. – Press in a new shaft seal ring with the open side facing inward until it stops. Info Support the clutch cover sufficiently when pressing in. –…

• Page 128
  ENGINE Main work – Position the crankshaft with the special tool in the press. Under part, pressing-out tool (75029047051) ( p. 220) – Position the special tool between the crankwebs. Upper part, pressing-out tool (75029047050) ( p. 220) – Press the crank pin with the push-out drift of the special tool out of the upper crankweb.

• Page 129: Checking Crankshaft Run-Out At Bearing Pin

  ENGINE – Position the special tool with the heel at the bottom. Pressing device for crankshaft, complete (75029047000) ( p. 219) – Press the upper crankweb in as far as possible. Info The press mandrel must be applied above the crank pin. –…

• Page 130: Installing Crankshaft Bearing Inner Ring

  ENGINE – Place the drive wheel on the crankshaft. The dowel of the crankshaft must fit in the drill hole The side of the drive wheel with the punch mark must be visible after assembly, and the side with the bevel must be in contact with the crankweb.

• Page 131: Cylinder — Nikasil ® Coating

  ENGINE » If the measured value does not equal the specified value: – Remove the crankshaft. – Remove the crankshaft bearing inner ring. ( p. 125) – Calculate the thickness of the compensation shims. – Add or remove compensation shims equally on both sides. Info If the axial clearance is too small, remove compensation shims.

• Page 132: Checking/Measuring The Piston

  ENGINE – The cylinder size is marked on the side of the cylinder. 300103-10 – Check the sealing area of the cylinder head for distortion using a straight edge and the special tool. Feeler gauge (59029041100) ( p. 216) ≤ 0.10 mm (≤ 0.0039 in) Cylinder/cylinder head — sealing area distortion »…

• Page 133: Checking Piston Ring End Gap

  ENGINE – Measure the piston at the piston skirt, at right angles to the piston pin, at a distance Guideline Distance 31.5 mm (1.24 in) Piston — diameter Size I 101.955… 101.965 mm (4.01397… 4.01436 in) Size II 101.965… 101.975 mm (4.01436… 4.01476 in) 302138-10 Info…

• Page 134: Replacing Autodecompressor

  ENGINE » If the measured value does not meet specifications: – Change the oil pump and, if necessary, the engine case. 17.4.17 Replacing autodecompressor – Take the lock ring off the autodecompression shaft and dispose of it. 300107-10 – Pull the autodecompression shaft from the camshaft.

• Page 135: Checking Timing Assembly

  ENGINE – Place two compensating disks or similar aids next to the piston of the timing chain tensioner. This should ensure that when pushed down, the piston does not fully withdraw. Guideline Thickness of the compensating disks 2… 2.5 mm (0.08… 0.098 in) –…

• Page 136: Changing Camshaft Bearing

  ENGINE – Screw a suitable screw into the rocker arm shafts . Pull out the rocker arm shafts. – Take off the rocker arm 300114-10 17.4.21 Changing camshaft bearing Preparatory work – Remove the rocker arm. ( p. 133) Main work –…

• Page 137: Removing Valves

  ENGINE 17.4.22 Removing valves – Take shims out of the valve spring retainers and lay them to one side according to their normal built-in position. 300115-10 – Pretension the valve springs using the special tool. Valve spring compressor (59029019000) ( p.

• Page 138: Checking Valve Springs

  ENGINE 17.4.24 Checking valve springs – Check the valve springs for fractures and wear (visual check). » If the valve spring is fractured or worn: – Change the valve spring. – Measure the valve spring lengths. Valve spring Minimum length (without valve 42.3 mm (1.665 in) spring cap) »…

• Page 139: Installing Valves

  ENGINE 17.4.27 Installing valves – Position the valve spring cap . Install new valve stem seals – Mount valves according to their normal built-in position. – Install the valve springs and the spring retainers. 0 0 5 0 0 4 0 0 1 0 0 2 0 0 3…

• Page 140: Disassembling The Antihopping Clutch

  ENGINE – Install and tighten the screws of the rocker arm shafts. Guideline Screw, rocker arm shaft 12 Nm (8.9 lbf ft) 300113-11 17.4.29 Disassembling the antihopping clutch – Clamp the clutch in a vise. Info Use soft jaws. – Carefully loosen and gradually remove the special tool 300120-10 –…

• Page 141
  ENGINE 0 0 bk 0 0 4 0 0 5 0 0 6 0 0 2 0 0 9 0 0 b l 0 0 1 0 0 b o 0 0 3 0 0 b n 0 0 b m 0 0 7 0 0 8 300123-01…

• Page 142: Preassembling The Antihopping Clutch

  ENGINE – Check clutch facing discs for discoloration and scoring. » If there is discoloration or scoring: – Change all clutch facing discs. – Check the thickness of clutch facing discs ≥ 2.5 mm (≥ 0.098 in) Clutch facing disc — thickness »…

• Page 143: Checking Shift Mechanism

  ENGINE 17.4.32 Checking shift mechanism – Check the shift forks (see ) for damage and wear (visual check). 0 0 A » If there is damage or wear: – 0 0 1 Change the shift fork and gear wheel pair. 0 0 4 0 0 1 –…

• Page 144: Disassembling The Main Shaft

  ENGINE 17.4.34 Disassembling the main shaft 301980-01 – Fix the main shaft in the vise with the geared end facing downward. Guideline Use soft jaws. – Remove stop disk and second-gear fixed gear – Remove the sixth-gear idler gear – Remove the split needle bearing and stop disk –…

• Page 145: Checking The Transmission

  ENGINE – Remove stop disk and first-gear idler gear – Remove needle bearing and stop disk – Remove fifth-gear sliding gear and lock ring – Remove stop disk and third-gear idler gear – Remove needle bearing and the fourth-gear idler gear –…

• Page 146: Assembling The Main Shaft

  ENGINE » If the sliding gear does not move easily: – Change the sliding gear or the main shaft. – Check sliding gears for smooth operation in the profile of countershaft » If the fixed gear does not move easily: –…

• Page 147: Assembling Countershaft

  ENGINE 17.4.38 Assembling countershaft Info Use new lock rings in every repair job. Preparatory work – Oil all parts carefully before assembling. – Check the transmission. ( p. 143) Main work 300128-02 – Fix the countershaft in the vise with the geared end facing downward. Guideline Use soft jaws –…

• Page 148: Checking The Starter Drive

  ENGINE 17.4.39 Checking the starter drive 300129-01 – Check the teeth and seating of the starter idler gear for damage and wear. » If there is damage or wear: – Replace the starter idler gear and/or needle bushing. – Check the teeth and seating of the torque limiter for damage and wear.

• Page 149: Checking Freewheel

  ENGINE – Compress the expansion ring and remove it, using suitable pliers. – Take the freewheel out of the primary gear. 300128-10 17.4.41 Checking freewheel – Insert the freewheel gear in the primary gear , turning the primary gear clock- wise;…

• Page 150: Engine Assembly

  ENGINE – Insert the lock ring into the groove with suitable pliers and check that it is seated correctly. 300127-11 17.5 Engine assembly 17.5.1 Installing transmission shafts – Clamp the right section of the engine case. Holder for engine assembly stand (75012001070) ( p.

• Page 151: Installing Crankshaft And Balancer Shaft

  ENGINE – Install the shift rail – Check the transmission for smooth operation. 300079-11 – Install the shim and lock ring of the countershaft. 300082-11 17.5.2 Installing crankshaft and balancer shaft – Mount the special tool on the alternator side of the crankshaft. Mounting sleeve (75029080000) ( p.

• Page 152: Installing Left Engine Case

  ENGINE 17.5.3 Installing left engine case – Mount the dowels. – Mount the O-ring – Degrease the sealing area. Apply the sealing compound to the left engine case half. Loctite ® 5910 302132-11 – Put on the left engine case half. If necessary, tap lightly with a rubber mallet and turn the transmission shafts.

• Page 153: Installing Locking Lever

  ENGINE 17.5.5 Installing locking lever – Position locking lever with sleeve and spring – Mount and tighten screw Guideline Screw, locking lever 10 Nm Loctite ® 243™ (7.4 lbf ft) 300069-11 17.5.6 Installing shift drum locating – Press locking lever down and position shift drum locating.

• Page 154: Installing Primary Gear

  ENGINE – Push on the starter idler gear with washer. Mount lock ring. – Push on the needle bearing and torque limiter with washer. Mount lock ring. 300064-11 17.5.9 Installing primary gear – Ensure that the spring washer is seated properly. –…

• Page 155: Installing Crankshaft Position Sensor

  ENGINE – Position a new lock washer and install the nut – Lock the clutch basket and primary gear using special tool and tighten the nut. Guideline Nut, inner clutch hub M20x1.5 100 Nm Loctite ® 243™ (73.8 lbf ft) Gear segment (75029081000) ( p.

• Page 156: Installing Timing Chain And Timing Chain Sprocket

  ENGINE 17.5.12 Installing timing chain and timing chain sprocket – Heat the timing chain sprocket and push it immediately on to the crankshaft. Guideline 100 °C (212 °F) – Mount lock ring 300150-10 – Thread the timing chain in and lay it over the timing chain sprocket. Info If the timing chain is not new, pay attention to the direction of travel.

• Page 157: Adjusting Crankshaft Position Sensor Distance

  ENGINE – Mount the tab washer and the nut . Tighten nut. Guideline Rotor nut M18x1.5 100 Nm (73.8 lbf ft) 300043-10 17.5.15 Adjusting crankshaft position sensor distance – Adjust the distance between the crankshaft position sensor and the conductive element of the rotor using the special tool Guideline Crankshaft position sensor/rotor -…

• Page 158
  ENGINE – Ensure that piston marking faces the outfeed side. 302599-10 – Apply a thin layer of sealing compound in area Loctite ® 5910 – Place the cylinder base gasket on. Info Make sure the grooved pins are seated correctly. 302598-10 –…

• Page 159: Installing Cylinder Head

  ENGINE – Remove the cloth. – Keep the timing chain tensioned. Push the cylinder down carefully and let the grooved pins engage. 300039-10 17.5.18 Installing cylinder head – Put on the cylinder head gasket. Info Make sure the grooved pins are seated correctly. –…

• Page 160: Installing Timing Chain Tensioner

  ENGINE – Position the camshaft support plate . Mount and tighten screw Guideline Screw, camshaft support 10 Nm Loctite ® 243™ plate (7.4 lbf ft) 300022-10 17.5.20 Installing timing chain tensioner – Insert the timing chain tensioner – Mount and tighten plug with the new seal ring.

• Page 161: Adjusting Valve Clearance

  ENGINE – Remove the special tool. Engine blocking screw (77329010000) ( p. 222) – Mount and tighten screw with the washer. Guideline Screw plug, crankshaft clamp 20 Nm (14.8 lbf ft) 306140-10 17.5.22 Adjusting valve clearance – Remove screws Info Make sure that the crankshaft is at top dead center.

• Page 162: Installing Spark Plug

  ENGINE 17.5.23 Installing spark plug – Mount and tighten the spark plug using the special tool. Guideline Spark plug M12x1.25 18 Nm (13.3 lbf ft) Spark plug wrench (75029172000) ( p. 222) 300016-11 17.5.24 Installing spacer and spring – Install the spacer and spring of the shift shaft.

• Page 163: Installing Thermostat

  ENGINE – Put on the water pump cover . Mount and tighten screws. Guideline Screw, water pump cover 10 Nm (7.4 lbf ft) 300012-12 17.5.27 Installing thermostat – Position the thermostat with the gasket. The drill hole must face upward. –…

• Page 164: Installing The Spacer

  ENGINE – Install the gear position sensor – Position the ground wire – Mount and tighten the screws. Guideline Loctite ® 243™ Screw, gear sensor 5 Nm (3.7 lbf ft) 302126-11 17.5.30 Installing the spacer – Grease spacer in area and O-ring before mounting.

• Page 165: Installing Alternator Cover

  ENGINE – Position the oil screen with O-rings. – Mount and tighten screw plug with the O-ring. Guideline Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) 300161-11 17.5.32 Installing alternator cover – Apply sealing compound lightly in the area of the cable sleeve. –…

• Page 166: Installing Valve Cover

  ENGINE 17.5.34 Installing valve cover – Put the valve cover in place with the seal. Mount and tighten screws Guideline Screw, valve cover 10 Nm (7.4 lbf ft) 300003-10 17.5.35 Removing the engine from the engine assembly stand – Remove the screw or the nut –…

• Page 167: Clutch

  CLUTCH 18.1 Checking/rectifying the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –…

• Page 168: Water Pump, Cooling System

  WATER PUMP, COOLING SYSTEM 19.1 Draining the coolant 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 169: Checking The Antifreeze And Coolant Level

  WATER PUMP, COOLING SYSTEM – Remove the cap from compensating tank and add coolant to the level shown in the figure. – Mount the cap of the compensating tank. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.

• Page 170: Checking The Coolant Level

  WATER PUMP, COOLING SYSTEM » If the coolant level does not meet specifications: – Correct the coolant level and find out the cause of the loss. Alternative 1 Coolant ( p. 210) Alternative 2 Coolant (mixed ready to use) ( p.

• Page 171: Lubrication System

  LUBRICATION SYSTEM 20.1 Oil circuit 400500-60 Oil circuit of force pump Oil screen Force pump Oil filter Oil pressure regulator valve Timing chain tensioner Rocker arm shaft Transmission Clutch Oil jet for piston cooling Oil filter Oil nozzle for conrod bearing lubrication Oil circuit of suction pump Oil screen Suction pump…

• Page 172: Checking The Engine Oil Pressure

  LUBRICATION SYSTEM Main work – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level. The engine oil must be between the lower and upper edge of the oil level viewer. » If the engine oil level is not at the specified level: –…

• Page 173: Changing The Engine Oil And Filter, Cleaning The Oil Screens

  LUBRICATION SYSTEM – Change the oil filter. Check oil pumps for wear. Check that all oil holes are clear. – Switch off the engine. Warning Danger of burns Some vehicle components get very hot when the machine is driven. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.

• Page 174: Removing The Oil Filter

  LUBRICATION SYSTEM – Thoroughly clean the oil drain plug with a magnet. – Mount the oil drain plug with the magnet and seal ring and tighten it. Guideline Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) 100201-01 20.6 Removing the oil filter Warning…

• Page 175: Cleaning The Oil Screens

  LUBRICATION SYSTEM 20.8 Cleaning the oil screens 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 176: Filling Up With Engine Oil

  LUBRICATION SYSTEM 20.9 Filling up with engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. Main work – Remove filler plug with O-ring from the clutch cover and add engine oil. Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60)

• Page 177: Ignition System

  IGNITION SYSTEM 21.1 Alternator — checking the stator winding Condition The stator is disconnected. Preparatory work – Remove the seat. ( p. 62) – Take off the side cover. ( p. 63) Main work Stator winding, measurement I — check the resistance –…

• Page 178: Ignition Coil — Checking The Secondary Winding

  IGNITION SYSTEM 21.3 Ignition coil — checking the secondary winding Condition Ignition coil cylinder 1 is disconnected. Spark plug connector cylinder 1 has been removed. Preparatory work – Remove the seat. ( p. 62) – Remove the fuel tank. Main work Ignition coil cylinder 1 — check the secondary winding resistance –…

• Page 179: Technical Data

  TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 690 cm³ (42.11 cu in) Stroke 84.5 mm (3.327 in) Bore 102 mm (4.02 in) Compression ratio 12.5:1 Control OHC, 4 valves controlled via rocker arm, chain drive Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust 34 mm (1.34 in)

• Page 180
  TECHNICAL DATA Exhaust 2.00 mm (0.0787 in) Valve — run-out ≤ 0.05 mm (≤ 0.002 in) On the valve plate ≤ 0.05 mm (≤ 0.002 in) On the valve stem ≤ 0.10 mm (≤ 0.0039 in) Cylinder/cylinder head — sealing area distortion Cylinder — bore diameter Size I 102.000……

• Page 181: Engine Tightening Torques

  TECHNICAL DATA 22.3 Engine tightening torques ® Screw, membrane fixation 2 Nm (1.5 lbf ft) Loctite 243™ – Hose clip, intake flange 2.5 Nm (1.84 lbf ft) ® Oil nozzle for conrod bearing lubrica- 2 Nm (1.5 lbf ft) Loctite 243™…

• Page 182: Capacities

  TECHNICAL DATA ® Screw plug, oil channel M10x1 15 Nm (11.1 lbf ft) Loctite 243™ – Screw plug, oil channel, for oil radiator M10x1 15 Nm (11.1 lbf ft) – Screw, unlocking of timing chain ten- M10x1 10 Nm (7.4 lbf ft) sioner –…

• Page 183: Electrical System

  Continental TKC 80 Continental TKC 80 (690 Enduro R USA) 90/90 — 21 M/C 54R TT 140/80 — 18 M/C 70R TT Pirelli MT 21 RALLYCROSS Pirelli MT 21 RALLYCROSS Additional information is available in the Service section under: http://www.ktm.com…

• Page 184: Fork

  TECHNICAL DATA 22.8 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 185: Chassis Tightening Torques

  TECHNICAL DATA 22.10 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 stand switch EJOT 2 Nm (1.5 lbf ft) –…

• Page 186
  TECHNICAL DATA – Screw, fork stub 15 Nm (11.1 lbf ft) ® Screw, front brake caliper 25 Nm (18.4 lbf ft) Loctite 243™ – Screw, front footrest bracket 25 Nm (18.4 lbf ft) – Screw, fuel tank bracket 15 Nm (11.1 lbf ft) ®…

• Page 187: Cleaning/Protective Treatment

  CLEANING/PROTECTIVE TREATMENT 23.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts.

• Page 188: Checks And Maintenance Steps For Winter Operation

  CLEANING/PROTECTIVE TREATMENT 23.2 Checks and maintenance steps for winter operation Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggres- sive road salt. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

• Page 189: Storage

  – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the lift stand. ( p. 10) – Cover the motorcycle with a tarp or similar cover that is permeable to air.

• Page 190: Service Schedule

  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 192: Wiring Diagram

  WIRING DIAGRAM 26.1 Page 01 of 10 wh-rd rd-bu wh-rd wh-rd wh-rd EM/3 EN/3 bl-rd rd-bu bl-rd ye-rd wh-rd ye-rd 602001-01…

• Page 193
  WIRING DIAGRAM Components: EFI control unit Fuse Battery Alternator Starter relay with main fuse Start auxiliary relay Starter motor Voltage regulator Connector for accessory ground (terminal 31) ACC 1 (not assigned) X291 X292 Connector for accessory plus (terminal 30) ACC 1 (not assigned)

• Page 194: 192

  WIRING DIAGRAM 26.2 Page 02 of 10 ye-rd bl-rd ye-rd ye-rd ye-rd bl-rd bl-rd bl-rd wh-rd wh-rd wh-rd wh-rd br-gr br-gr wh-rd bl-rd ye-rd wh-bl wh-bl ye-rd wh-rd ye-rd ye-rd 602002-01…

• Page 195
  WIRING DIAGRAM Components: EFI control unit EPT control unit Fuse Light relay Power relay Combination instrument Ignition/steering lock Emergency OFF switch, electric starter button X295 Diagnostics connector…

• Page 196: 194

  WIRING DIAGRAM 26.3 Page 03 of 10 ye-bu ye-bu 602003-01…

• Page 197
  WIRING DIAGRAM Components: Low beam, high beam Fuse Fuse Combination instrument Horn Parking light High beam/low beam switch, horn button, turn signal switch…

• Page 198: 196

  WIRING DIAGRAM 26.4 Page 04 of 10 wh-gn ye-bu wh-gn ye-bu wh-gn 602004-01…

• Page 199
  WIRING DIAGRAM Components: Front brake light switch Brake light switch, rear License plate lamp Brake/tail light…

• Page 200: 198

  WIRING DIAGRAM 26.5 Page 05 of 10 bl-or ye-bu bl-or 602005-01…

• Page 201
  WIRING DIAGRAM Components: Turn signal relay Combination instrument Turn signal, front left Turn signal, front right Turn signal, rear left Turn signal, rear right High beam/low beam switch, horn button, turn signal switch…

• Page 202: 200

  WIRING DIAGRAM 26.6 Page 06 of 10 bl-rd bl-rd wh-bl wh-bl 602006-01…

• Page 203
  WIRING DIAGRAM Components: Temperature switch for radiator fan Fuse Fuse Radiator fan X293 Connector for accessory ground (terminal 31) ACC 2 (not assigned) X294 Connector for accessory plus (terminal 15) ACC 2 (not assigned)

• Page 204: 202

  WIRING DIAGRAM 26.7 Page 07 of 10 br-pu br-pu br-pu br-pu ye-rd br-pu bl-bu bu-gr bu-gr wh-br gn-or wh-bu bl-bu bl-bu ye-rd bu-or ye-rd bl-bu wh-bu gn-or wh-br br-pu bu-or bu-br bu-br wh-gn wh-gn wh-rd wh-rd wh-or wh-or 602007-01…

• Page 205
  WIRING DIAGRAM Components: EFI control unit EPT control unit Fuse Fuse Fuse Fuel pump Throttle stepper motor Combination instrument…

• Page 206: 204

  WIRING DIAGRAM 26.8 Page 08 of 10 bl-or bl-or rd-gr rd-gr bl-gr bl-gr wh-pu wh-pu gn-rd gn-rd wh-bu wh-bu bu-br bu-br bl-or bl-or 602008-01…

• Page 207
  WIRING DIAGRAM Components: EFI control unit Lambda sensor (cylinder 1) Front wheel speed sensor Fuel evaporation valve (USA version only) Secondary air valve Injector (cylinder 1) Combination instrument Ignition coil (cylinder 1)

• Page 208: 206

  WIRING DIAGRAM 26.9 Page 09 of 10 ye-gn ye-gn wh-pk wh-pk ye-or ye-or ye-br ye-br bl-gn bl-gn gn-gr bl-gn gn-gr 602009-01…

• Page 209
  WIRING DIAGRAM Components: EFI control unit Throttle position sensor circuit A Intake air temperature sensor Rollover sensor Side stand switch Accelerator position sensor Gear position sensor Oil pressure sensor Combination instrument…

• Page 210: 208

  WIRING DIAGRAM 26.10 Page 10 of 10 gn-gr gn-gr wh-ye wh-ye ye-bu ye-bu bl-br bl-br bl-ye bl-ye bu-or bu-or br-rd br-rd 602010-01…

• Page 211
  WIRING DIAGRAM Components: EFI control unit Ambient air pressure sensor Engine coolant temperature sensor (cylinder 1) Fuel tank sensor Crankshaft position sensor Clutch switch Manifold absolute pressure sensor (cylinder 1) Combination instrument Map‑Select Switch Cable colors: Black Brown Blue Green Gray Light blue Orange…

• Page 212: Substances

  Brake fluid DOT 4 / DOT 5.1 According to – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Castrol and Motorex ® products. Supplier Castrol –…

• Page 213
  Hydraulic fluid (15) According to – 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 ® –…

• Page 214: 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 215
  AUXILIARY SUBSTANCES Lubricant (T625) Guideline – KTM recommends Molykote ® products. Supplier Molykote ® – 33 Medium Motorcycle cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Moto Clean 900 Off-road chain spray Guideline – KTM recommends Motorex ®…

• Page 216: Special Tools

  SPECIAL TOOLS Bleeder cover Art. no.: 00029013004 201830-10 Bleeder cover Art. no.: 00029013009 201831-10 Bleeding device Art. no.: 00029013100 201491-10 Bearing puller Art. no.: 15112017000 400037-01 Insert for bearing puller Art. no.: 15112018100 Feature 18… 23 mm (0.71… 0.91 in) 400125-01…

• Page 217
  SPECIAL TOOLS Bleed syringe Art. no.: 50329050000 400058-01 Circlip pliers reverse Art. no.: 51012011000 400059-01 Extractor Art. no.: 58429009000 400073-01 Tool for inner bearing race Art. no.: 58429037043 400082-01 Mounting sleeve Art. no.: 58529005000 400095-01…
• Page 218
  SPECIAL TOOLS Valve spring compressor Art. no.: 59029019000 400101-01 Limit plug gauge Art. no.: 59029026006 400104-01 Extractor Art. no.: 59029033000 400105-01 Feeler gauge Art. no.: 59029041100 400110-01 Hose clamp pliers Art. no.: 60029057000 400142-01…
• Page 219
  SPECIAL TOOLS Pliers for spring band clamp Art. no.: 60029057100 400085-01 Testing hose Art. no.: 61029093000 201314-01 Pressure testing tool Art. no.: 61029094000 400149-01 Engine assembly stand Art. no.: 61229001000 200306-01 Work stand Art. no.: 62529055000 400151-01…
• Page 220
  SPECIAL TOOLS Support for engine assembly stand Art. no.: 75012001060 400153-01 Holder for engine assembly stand Art. no.: 75012001070 400154-01 Piston assembly ring Art. no.: 75029015102 400156-01 Extractor Art. no.: 75029021000 400157-01 Assembly screws Art. no.: 75029033000 400158-01…
• Page 221
  SPECIAL TOOLS Insertion for piston ring lock Art. no.: 75029035000 400160-01 Work stand adapter Art. no.: 75029036000 400161-01 Push-in drift Art. no.: 75029044010 500163-01 Push-in drift Art. no.: 75029044020 500162-01 Pressing device for crankshaft, complete Art. no.: 75029047000 400185-01…
• Page 222
  SPECIAL TOOLS Upper part, pressing-out tool Art. no.: 75029047050 400186-01 Under part, pressing-out tool Art. no.: 75029047051 400187-01 Extractor Art. no.: 75029048000 400162-01 Clamping plate Art. no.: 75029050000 400163-01 Push-out drift Art. no.: 75029051000 400164-01…
• Page 223
  SPECIAL TOOLS Floor jack attachment Art. no.: 75029055000 400184-01 Mounting sleeve Art. no.: 75029080000 400165-01 Gear segment Art. no.: 75029081000 400068-01 Protection cover Art. no.: 75029090000 400167-01 Holding spanner Art. no.: 75029091000 400168-01…
• Page 224
  SPECIAL TOOLS Spark plug wrench Art. no.: 75029172000 400170-01 Oil pressure adapter Art. no.: 77329006000 400176-01 Engine blocking screw Art. no.: 77329010000 400177-01 Release device for timing chain tensioner Art. no.: 77329051000 400181-01 Valve spring mounting device Art. no.: 78029060000 500165-01…
• Page 225
  SPECIAL TOOLS Hook wrench Art. no.: T106S 301085-01 Depth micrometer Art. no.: T107S 300577-10 Art. no.: T120 201235-10 Pressing tool Art. no.: T1206 200583-10 Pressing tool Art. no.: T1207S 200585-01…
• Page 226
  SPECIAL TOOLS Vacuum pump Art. no.: T1240S 200273-10 Pressing tool Art. no.: T129 200584-01 Protecting sleeve Art. no.: T1401 200635-10 Clamping stand Art. no.: T14015S 200733-10 Clamping stand Art. no.: T14016S 200688-10…
• Page 227
  SPECIAL TOOLS Gripping tool Art. no.: T14026S1 200639-10 Assembly tool Art. no.: T1402S 200634-10 Open-end wrench Art. no.: T14032 200640-10 Clamping stand Art. no.: T1403S 200637-10 Mounting sleeve Art. no.: T1515 300569-10…
• Page 228
  SPECIAL TOOLS Nitrogen filling tool Art. no.: T170S1 300574-10…

• Page 229: 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 specifi- cation.

• Page 230: Index

  INDEX front brake, removing ……74 INDEX rear brake, installing ……77 Accessories .

• Page 231
  INDEX freewheel, removing ……146 left engine case section ….. . 123 Disassembling the engine main shaft, assembling .
• Page 232
  INDEX fork, servicing ……17 Oil filter installing ……. . . 16 changing .
• Page 233
  INDEX Side cover mounting ……. . 63 removing ……. . . 63 Spare parts .
• Page 234
  *3206150en* 3206150en 10/2012 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com…

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

• Page 1
  OWNER’S MANUAL 2018 690 Enduro R Art. no. 3213745en…
• Page 3
  DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art DEAR KTM CUSTOMER sports motorcycle that will give you enormous pleasure if you service and maintain it properly. We hope you enjoy your new ride! Enter the serial numbers of your vehicle below.
• Page 4
  Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assur- ance processes that lead to the maximum possible quality of the products. Issued by: TÜV Management Service KTM Sportmotorcycle GmbH Stallhofnerstraße 3…

• Page 5: Table Of Contents

  TABLE OF CONTENTS VIEW OF VEHICLE ……..20 TABLE OF CONTENTS MEANS OF REPRESENTATION …… 9 View of vehicle, front left (example) … 20 Symbols used ……..9 View of vehicle, rear right Formats used……..10 (example)……..22 SAFETY ADVICE………. 11 SERIAL NUMBERS ……..

• Page 6
  TABLE OF CONTENTS 6.10 Combination instrument ….32 PREPARING FOR USE……… 50 6.10.1 Combination instrument Advice on preparing for first use ..50 overview……..32 Running in the engine …… 52 6.10.2 Function buttons ……33 Loading the vehicle ……53 6.10.3 Tachometer ………
• Page 7
  TABLE OF CONTENTS 10.3 Adjusting the rebound damping of 11 SERVICE WORK ON THE CHASSIS….95 the fork……….. 80 11.1 Raising the motorcycle with a lift 10.4 Compression damping of the shock stand ……….95 absorber………. 81 11.2 Removing the motorcycle from the 10.5 Adjusting the low-speed lift stand ………
• Page 8
  TABLE OF CONTENTS 11.18 Adjusting the basic position of the 12.13 Changing the rear brake linings ..143 clutch lever ……..117 13 WHEELS, TIRES ……..148 11.19 Checking/correcting the fluid level 13.1 Removing the front wheel …. 148 of the hydraulic clutch….118 11.20 Removing the engine guard…..
• Page 9
  TABLE OF CONTENTS 14.10 Changing the parking light bulb..183 17.2 Changing the engine oil and filter, cleaning the oil screens ….208 14.11 Changing the turn signal bulb ..184 14.12 Checking the headlight setting ..186 17.3 Draining the engine oil ….
• Page 10
  TABLE OF CONTENTS 22.3.2 Coolant ……..244 22.3.3 Fuel ……… 244 22.4 Chassis ……… 244 22.5 Electrical system……246 22.6 Tires ……….247 22.7 Fork……….248 22.8 Shock absorber ……249 22.9 Chassis tightening torques ….250 23 SUBSTANCES ………. 257 24 AUXILIARY SUBSTANCES ……

• Page 11: Means Of Representation 1

  All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop! Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary tools required.

• Page 12: Formats Used

  1 MEANS OF REPRESENTATION Indicates a voltage measurement. Indicates a current measurement. Indicates the end of an activity, including potential rework. Formats used The typographical formats used in this document are explained below. Proprietary name Indicates a proprietary name. Name ®…

• Page 13: Safety Advice 2

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

• Page 14: Degrees Of Risk And Symbols

  2 SAFETY ADVICE Info Various information and warning labels are attached in prominent locations on the model described. Do not remove any information or warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured. Degrees of risk and symbols Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the…

• Page 15: Tampering Warning

  SAFETY ADVICE 2 Tampering warning Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof: 1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replace- ment, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any…

• Page 16: Protective Clothing

  An appropriate driver’s license is needed to ride the vehicle on public roads. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.

• Page 17: Work Rules

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

• Page 18: Owner’s Manual

  The Owner’s Manual is an important component of the vehicle and must be handed over to the new owner if the vehicle is sold. The Owner’s Manual is also available for download from your authorized KTM dealer and on the KTM website. International KTM Website: http://www.ktm.com…

• Page 19: Important Notes 3

  Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void.

• Page 20: Service

  Please follow the instructions in the text. Customer service Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.

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

• Page 22: View Of Vehicle

  4 VIEW OF VEHICLE View of vehicle, front left (example) S02176-10…

• Page 23
  VIEW OF VEHICLE 4 Hand brake lever ( p. 27) Clutch lever ( p. 27) Handrails ( p. 46) Filler cap Passenger footrest ( p. 46) Seat unlocking ( p. 45) Side stand ( p. 48) Shift lever ( p. 47) Engine number ( p.

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

  4 VIEW OF VEHICLE View of vehicle, rear right (example) S02177-10…

• Page 25
  VIEW OF VEHICLE 4 Ignition/steering lock ( p. 31) Light switch ( p. 29) Turn signal switch ( p. 29) Horn button ( p. 28) Function buttons ( p. 33) Indicator lamps ( p. 34) Emergency OFF switch ( p. 30) Electric starter button ( p.

• Page 26: Serial Numbers

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

• Page 27: Key Number

  SERIAL NUMBERS 5 Key number The key number can be found on the KEYCODECARD. Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place. 402241-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.

• Page 28: Fork Part Number

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

• Page 29: Controls 6

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

• Page 30: Throttle Grip

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

• Page 31: Light Switch

  CONTROLS 6 Light switch The light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is turned downward. In this position, the low beam and tail light are switched High beam on – Light switch is turned upward. In this position, the high beam and tail light are switched on.

• Page 32: Emergency Off Switch

  6 CONTROLS To switch off the turn signal light, press the turn signal switch towards the switch case. Emergency OFF switch The emergency OFF switch is fitted on the right side of the handlebar. Possible states Emergency OFF switch off – In this position, the igni- tion circuit is interrupted, a running engine stops, and the engine cannot be started.

• Page 33: Electric Starter Button

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

• Page 34: Combination Instrument

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

• Page 35: Function Buttons

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

• Page 36: Indicator Lamps

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

• Page 37: Display

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

• Page 38: Speed Display

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

• Page 39: Setting The Kilometers Or Miles

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

• Page 40: Time

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

• Page 41: 6.10.10 Odo Display

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

• Page 42: Setting/Resetting Display Trip 2

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

• Page 43: 6.10.13 Trip F Display

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

• Page 44: 6.10.14 Gear Display

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

• Page 45: Opening The Filler Cap

  CONTROLS 6 6.11 Opening the filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –…

• Page 46
  6 CONTROLS Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to enter the groundwater, the soil, or the sewage system. – Lift cover of filler cap and insert the ignition key. –…

• Page 47: Closing Filler Cap

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

• Page 48: Handrails

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

• Page 49: Shift Lever

  CONTROLS 6 6.16 Shift lever The shift lever is mounted on the left side of the engine. 401950-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11…

• Page 50: Foot Brake Lever

  6 CONTROLS 6.17 Foot brake lever Foot brake lever is located in front of the right footrest. The rear brake is engaged with the foot brake lever. 401956-10 6.18 Side stand The side stand is located on the left side of the vehicle. The side stand is used for parking the motorcycle.

• Page 51
  CONTROLS 6 Side stand folded in – This position is mandatory when riding • the motorcycle. The safety starting system is inactive.

• Page 52: Preparing For Use

  Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel. Warning Danger of accidents Non-approved or non-recommended tires and wheels impact the handling character- istic. – Only use tires/wheels approved by KTM with the corresponding speed index.

• Page 53
  When using your vehicle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.

• Page 54: Running In The Engine

  7 PREPARING FOR USE – Get used to handling the motorcycle in a suitable area before making a longer trip. Try also to ride as slowly as possible and in a standing position to get a better feeling for the motorcycle. –…

• Page 55: Loading The Vehicle

  PREPARING FOR USE 7 Loading the vehicle Warning Danger of accidents Total weight and axle loads influence the handling characteristic. The overall weight consists of: motorcycle ready for operation and with a full tank, driver and passenger with protective clothing and helmet, and luggage. –…

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

• Page 58: Riding Instructions

  8 RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is roadworthy. The vehicle must be in perfect technical condition when it is being operated. –…

• Page 59: Starting The Vehicle

  RIDING INSTRUCTIONS 8 Starting the vehicle Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space. Caution Danger of accidents Electronic components and safety devices will be damaged if the battery is discharged or missing.

• Page 60
  8 RIDING INSTRUCTIONS – Turn the emergency OFF switch to the position – Switch on the ignition by turning the ignition key to position ON After you switch on the ignition, you can hear the fuel pump working for about two seconds. The function check of the combination instrument is run at the same time.
• Page 61
  RIDING INSTRUCTIONS 8 Info Do not press the electric starter button until the combi- nation instrument function check is finished. When starting, DO NOT open the throttle. If you open the throttle during the starting procedure, fuel is not injected by the engine management system and the engine cannot start.

• Page 62: Starting Off

  8 RIDING INSTRUCTIONS Switching off ABS KTM recommends riding with ABS at all times. However, situa- tions may arise in which ABS is not advantageous. Condition Vehicle stationary, engine running. – for 3 – 5 seconds. Press button The ABS warning lamp starts flashing; ABS is deactivated.

• Page 63
  RIDING INSTRUCTIONS 8 Warning Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine races. – Do not change into a low gear at high engine speed. Warning Danger of accidents An incorrect ignition key position causes malfunctions. –…
• Page 64
  8 RIDING INSTRUCTIONS Warning Danger of accidents Cold tires have reduced road grip. – Ride the first miles carefully on every journey at moderate speed until the tires reach operating tem- perature. Warning Danger of accidents New tires have reduced road grip. The contact surface on new tires is not yet roughened.
• Page 65
  Check and, if necessary, correct the coolant level on the cooling system while it is in a cooled state. Info If unusual noises arise during operation, stop immediately, switch off the engine, park the vehicle prop- erly, and contact an authorized KTM workshop.
• Page 66
  8 RIDING INSTRUCTIONS – Shift into a higher gear when conditions allow (incline, road situation, etc.). – Release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever, and open the throttle. Info You can see the positions of the 6 forward gears in the figure.
• Page 67
  RIDING INSTRUCTIONS 8 – If the engine stalls (e.g. at a crossroads), just pull the clutch lever and press the electric starter button. You do not have to shift into neutral. – Switch off the engine if running at idle or stationary for a long time.

• Page 68: Applying The Brakes

  Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents The brake system fails in the event of overheating.

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

• Page 70: Stopping, Parking

  8 RIDING INSTRUCTIONS – Use the braking effect of the engine on long downhill stretches. Change down one or two gears, but do not over-rev the engine. You will have to apply the brakes far less frequently as a result and the brake system will not overheat.

• Page 71
  RIDING INSTRUCTIONS 8 Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive. – Allow the vehicle to cool down before covering it. –…

• Page 72: Transport

  8 RIDING INSTRUCTIONS Transport Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive. –…

• Page 73: Refueling

  RIDING INSTRUCTIONS 8 Refueling Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. – Switch off the engine for refueling.

• Page 74
  In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Improper handling of fuel is a danger to the environment.
• Page 75
  RIDING INSTRUCTIONS 8 – Press the SET button for two seconds. The fuel level warning lamp goes out. TRIP F is set to 0.0 and the display returns to the previous display mode. Info If you do not press the SET button , the reset takes place automatically after approx.

• Page 76: Service Schedule

  Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.

• Page 77
  SERVICE SCHEDULE 9 after every sporting use Every two years Every year every 20,000 km (12,400 mi) every 10,000 km (6,200 mi) after 1,000 km (620 mi) ● Change the front brake fluid. ● Change the rear brake fluid. ● Change the hydraulic clutch fluid.
• Page 78
  Final check: Check the vehicle is roadworthy and take a test ride. ○ ● ● ● ● ● Read out the fault memory using the KTM diagnostics tool after a test ride. ● ● ● Check the CO adjustment using the KTM diagnostics tool. ○ ●…

• Page 79: Recommended Work

  SERVICE SCHEDULE 9 Recommended work after every sporting use Every four years Every year every 30,000 km (18,600 mi) every 10,000 km (6,200 mi) after 1,000 km (620 mi) ● Check the frame. ● Check the swingarm. ● ● Check the swingarm bearing for play. ●…

• Page 80: 10 Tuning The Chassis

  10 TUNING THE CHASSIS 10.1 Fork/shock absorber The fork and the shock absorber offer many options of adapting the chassis to your riding style and the payload. Info To help you adapt the vehicle, we have summarized our findings in Table .

• Page 81
  TUNING THE CHASSIS 10 – Turn the white adjusting screw all the way clockwise. Info Adjusting screw is located at the upper end of the left fork leg. The compression damping is located in the left fork leg COMP (white adjusting screw). The rebound damp- ing is located in the right fork leg REB (red adjusting screw).

• Page 82: Adjusting The Rebound Damping Of The Fork

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

• Page 83: Compression Damping Of The Shock Absorber

  Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.)

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

• Page 85: Adjusting The High-Speed Compression Damping Of The Shock Absorber

  The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber.

• Page 86: Adjusting The Rebound Damping Of The Shock Absorber

  Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.)

• Page 87: Measuring The Unloaded Rear Wheel Sag

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

• Page 88
  10 TUNING THE CHASSIS Main work – Measure the distance – as vertical as possible – between the rear axle and a fixed point, for example, a mark on the rear 0 0 A fairing. – Note down the value as dimension 400988-10 Finishing work –…

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

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

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

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

• Page 91: Adjusting The Spring Preload Of The Shock Absorber

  The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.

• Page 92
  10 TUNING THE CHASSIS Main work – Release retaining ring – Turn adjusting ring until the spring is fully relaxed. Hook wrench (T106S) – Measure the overall spring length without a load. – Tighten the spring by turning adjusting ring to the speci- fied measurement.

• Page 93: Adjusting The Riding Sag

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

• Page 94: Handlebar Position

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

• Page 95: Adjusting Handlebar Position

  TUNING THE CHASSIS 10 10.14 Adjusting handlebar position – Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against damage. Do not bend the cables and lines. –…

• Page 96
  10 TUNING THE CHASSIS – Position the handlebar clamps. Mount screws and tighten evenly. Guideline Screw, handlebar 20 Nm (14.8 lbf ft) clamp…

• Page 97: Service Work On The Chassis 11

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

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

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

• Page 99
  SERVICE WORK ON THE CHASSIS 11 Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when nec- essary.

• Page 100: Loosening The Fork Protection

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

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

  Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam- ages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.

• Page 102
  11 SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable on the steering head bearing. » If there is detectable play: –…

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

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

• Page 104: Removing The Seat

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

• Page 105: Removing The Air Filter

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

• Page 106: Installing The Air Filter

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

• Page 107: Checking The Chain For Dirt

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

• Page 108: Cleaning The Chain

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

• Page 109: Checking The Chain Tension

  SERVICE WORK ON THE CHASSIS 11 Main work – Rinse off loose dirt with a soft jet of water. – Remove old grease residue with chain cleaner. Chain cleaner ( p. 261) – After drying, apply chain spray. Off-road chain spray ( p.

• Page 110
  11 SERVICE WORK ON THE CHASSIS – Lean the motorcycle on the side stand. – Shift gear to neutral. – Push the chain upward at a distance from the chain slid- ing guard and determine the chain tension Info The upper chain section must be taut.

• Page 111: Adjusting The Chain Tension

  SERVICE WORK ON THE CHASSIS 11 11.15 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

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

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

  SERVICE WORK ON THE CHASSIS 11 11.16 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 95) Main work – Shift the transmission to idle. – Check the rear sprocket and engine sprocket for wear. »…

• Page 114
  11 SERVICE WORK ON THE CHASSIS – Pull at the top part of the chain with the specified weight Guideline Weight of chain wear mea- 15 kg (33 lb.) 0 0 A surement – Measure distance of 18 chain rollers in the lower chain section.
• Page 115
  SERVICE WORK ON THE CHASSIS 11 – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with or below the chain sliding guard: – Replace the chain sliding guard. – Check that the chain sliding guard is firmly seated.
• Page 116
  11 SERVICE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated.
• Page 117
  SERVICE WORK ON THE CHASSIS 11 – Check the chain guide for wear. Info Wear can be seen on the front of the chain guide. » If the light part of the chain guide is worn: – Change the chain guide. 400985-01 –…

• Page 118: Adjusting Chain Guide

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

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

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

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

  11 SERVICE WORK ON THE CHASSIS 11.19 Checking/correcting the fluid level of the hydraulic clutch Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. –…

• Page 121
  SERVICE WORK ON THE CHASSIS 11 Info The fluid level rises with increasing wear of the clutch facing discs. Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts.

• Page 122: Removing The Engine Guard

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

• Page 123: Installing The Engine Guard

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

• Page 124: 12 Brake System

  Do not make any changes to the suspension travel. – Only use spare parts on the brake system which have been approved and recommended by KTM. – Only use tires/wheels approved by KTM with the corre- sponding speed index. – Maintain the specified tire air pressure. –…

• Page 125
  BRAKE SYSTEM 12 Warning Danger of accidents Driving aids can only prevent a rollover within the physical limitations. It is not always possible to compensate for extreme riding situations, for example with luggage loaded with a high center of gravity, varying road surfaces, steep descents or full braking without disengaging the gear.

• Page 126: Adjusting The Basic Position Of The Hand Brake Lever

  12 BRAKE SYSTEM ditions, for example when making «wheelies» or if the rear wheel spins. This causes the ABS to switch off. To reactivate the ABS, the vehicle must be stopped and the ignition switched off. The ABS is reactivated when the vehicle is switched on again.

• Page 127: Checking The Brake Discs

  Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the front and rear brake disc thickness at multiple…

• Page 128: Checking Brake Fluid Level Of Front Brake

  KTM workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)

• Page 129: Topping Up Brake Fluid Of Front Brake

  If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)

• Page 130
  Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
• Page 131
  BRAKE SYSTEM 12 Info Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container.

• Page 132: Checking The Front Brake Linings

  Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Damaged brake discs reduce the braking effect.

• Page 133: Changing The Front Brake Linings

  131) B01959-01 12.7 Changing the front brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.)

• Page 134
  – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect.
• Page 135
  Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
• Page 136
  12 BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Press the brake caliper by hand onto the brake disc in order to retract the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does.
• Page 137
  BRAKE SYSTEM 12 – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. – Insert the new brake linings, insert the pin, and mount the cot- ter pin. Info Always change the brake linings in pairs. –…

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

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

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

  BRAKE SYSTEM 12 12.9 Adjusting the basic position of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.

• Page 140
  12 BRAKE SYSTEM – Loosen fittings on foot brake cylinder – To adjust the basic position of the foot brake lever individually, loosen nut and turn screw accordingly. Info The range of adjustment is limited. The screw must be screwed into the footrest bracket by at least four turns. –…

• Page 141: Checking Rear Brake Fluid Level

  Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.

• Page 142: Adding Rear Brake Fluid

  If the brake fluid level drops below the MIN marking, the brake system is leaking or the brake linings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation. –…

• Page 143
  Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

• Page 144: Checking The Rear Brake Linings

  Clean up overflowed or spilt brake fluid immediately with water. 12.12 Checking the rear brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.)

• Page 145: Changing The Rear Brake Linings

  143) B01962-01 12.13 Changing the rear brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.)

• Page 146
  – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect.
• Page 147
  Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
• Page 148
  12 BRAKE SYSTEM – Stand the vehicle upright. – Remove screw cap with membrane – Press the brake caliper by hand onto the brake disc in order to retract the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does.
• Page 149
  BRAKE SYSTEM 12 – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. – Insert the new brake linings, insert the pin, and mount the cot- ter pin. Info Always change the brake linings in pairs. –…

• Page 150: 13 Wheels, Tires

  13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 95) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.

• Page 151
  WHEELS, TIRES 13 Warning Danger of accidents Damaged brake discs reduce the braking effect. – Always lay the wheel down in such a way that the brake disc is not damaged. – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork.

• Page 152: Installing The Front Wheel

  13 WHEELS, TIRES 13.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –…

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

• Page 154: Removing The Rear Wheel

  13 WHEELS, TIRES Guideline Screw, wheel speed 6 Nm (4.4 lbf ft) sensor 13.3 Removing the rear wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 95) Main work – Remove screw and pull wheel speed sensor out of the hole.

• Page 155
  WHEELS, TIRES 13 – Holding the rear wheel, withdraw wheel spindle B01969-10 – Push the rear wheel forward as far as possible and take the chain off the rear sprocket. Warning Danger of accidents Damaged brake discs reduce the braking effect. –…

• Page 156: Installing The Rear Wheel

  13 WHEELS, TIRES 13.4 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Warning Danger of accidents There is no braking effect to start with at the rear brake after installing the rear wheel.

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

• Page 158: Checking The Rear Hub Rubber Dampers

  13 WHEELS, TIRES – Position wheel speed sensor in the drill hole. Mount and tighten screw Guideline Screw, wheel speed 6 Nm (4.4 lbf ft) sensor – Operate the foot brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure point.

• Page 159
  WHEELS, TIRES 13 Main work – Check bearing » If the bearing is damaged or worn: – Replace the bearings. – Check rubber dampers of the rear hub for damage and wear. » If the rubber dampers of the rear hub are damaged or worn: S02205-10 –…

• Page 160: Checking The Tire Condition

  Warning Danger of accidents If a tire bursts while riding, the vehicle becomes uncontrollable. – Ensure that damaged or worn tires are replaced immediately. (Your authorized KTM workshop will be glad to help.) Warning Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling charac- teristic.

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

• Page 162: Checking The Tire Air Pressure

  DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. KTM recommends that the tires be changed after 5 H01144-10 years at the latest, regardless of the actual state of wear.

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

• Page 164: Checking The Spoke Tension

  Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes.

• Page 165
  WHEELS, TIRES 13 – Briefly strike each spoke with a screwdriver blade. Info The frequency of the tone is a function of the spoke length and spoke diameter. If you hear different tone frequencies from individual spokes of the same length and thickness, this is an indication of different spoke tensions.

• Page 166: 14 Electrical System

  14 ELECTRICAL SYSTEM 14.1 Removing the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and safety glasses. – Avoid contact with battery acid and battery gases. –…

• Page 167
  ELECTRICAL SYSTEM 14 Main work – Remove battery cover – Pull engine electronics control unit off of the holder and set it to one side. B01974-10 – Disconnect negative cable from the battery. – Take off positive terminal cover S00622-10…
• Page 168
  14 ELECTRICAL SYSTEM – Disconnect ABS connection cable and positive cable from the battery. S00620-10 – Remove screws – Pull retaining bracket of the battery forward and remove it. – Lift the battery up and out. Info Never operate the motorcycle with a discharged battery or without a battery.

• Page 169: Installing The Battery

  ELECTRICAL SYSTEM 14 14.2 Installing the battery Main work – Insert the battery into the battery compartment with the termi- nals facing rearward. Battery (YTZ10S) ( p. 246) – Position retaining bracket and mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) S00621-11 chassis…

• Page 170
  14 ELECTRICAL SYSTEM – Position positive terminal cover – Position washer and negative cable , and mount and tighten the screw. Guideline Screw, battery termi- 4.5 Nm (3.32 lbf ft) S00622-11 – Position the engine electronics control unit – Mount battery cover S00624-10 Finishing work –…

• Page 171: Recharging The Battery

  ELECTRICAL SYSTEM 14 14.3 Recharging the battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and safety glasses. – Avoid contact with battery acid and battery gases. –…

• Page 172
  14 ELECTRICAL SYSTEM Info Even when there is no load on the battery, it still loses power steadily. The charging level and the method of charging are very important for the service life of the battery. Rapid recharging with a high charging current shortens the battery’s service life. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves.
• Page 173
  ELECTRICAL SYSTEM 14 Main work – Connect the battery charger to the battery. Switch on the bat- tery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the battery.

• Page 174: Changing The Main Fuse

  14 ELECTRICAL SYSTEM – Set the clock. ( p. 38) 14.4 Changing the main fuse Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle.

• Page 175
  ELECTRICAL SYSTEM 14 Main work – Take off protection caps B01977-10 – Remove a defective main fuse with needle nose pliers. Info A defective fuse is indicated by a burned-out fuse wire A spare fuse is located in the starter relay. –…

• Page 176: Changing The Abs Fuses

  14 ELECTRICAL SYSTEM Finishing work – Mount the seat. ( p. 102) – Set the clock. ( p. 38) 14.5 Changing the ABS fuses Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. –…

• Page 177
  ELECTRICAL SYSTEM 14 To change the fuse of the ABS hydraulic unit: – Take off protection cap and remove the fuse. – Insert a new fuse. Fuse (58011109115) ( p. 246) – Mount the protection cap. B01979-10 To change the fuse of the ABS return pump: –…

• Page 178: Changing The Fuses Of Individual Power Consumers

  14 ELECTRICAL SYSTEM 14.6 Changing the fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work – Switch off the ignition by turning the ignition key to position OFF –…

• Page 179
  ELECTRICAL SYSTEM 14 – Remove the faulty fuse. Guideline Fuse 1 — 10 A — ignition Fuse 2 — 10 A — ignition, combination instrument, engine electronics control unit, lambda sensor Fuse 3 — 10 A — fuel pump Fuse 4 — 10 A — radiator fan Fuse 5 — 10 A — horn, brake light, turn signal S02238-10 Fuse 6 — 15 A — high beam, low beam, parking light, tail…
• Page 180
  14 ELECTRICAL SYSTEM Warning Fire hazard Incorrect fuses overload the electrical sys- tem. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. – Use spare fuses with the correct rating only. Fuse (75011088010) ( p.

• Page 181: Removing The Headlight Mask With The Headlight

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

• Page 182: Installing The Headlight Mask With The Headlight

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

• Page 183: Changing The Headlight Bulb

  ELECTRICAL SYSTEM 14 – Position line guides . Mount and tighten screws Guideline Screw, headlight 5 Nm (3.7 lbf ft) mask B01982-11 Finishing work – Check the headlight setting. ( p. 186) 14.9 Changing the headlight bulb Note Damage to reflector Grease on the reflector reduces the brightness. Grease on the bulb will evaporate due to the heat and be deposited on the reflector.

• Page 184
  14 ELECTRICAL SYSTEM Main work – Unplug connector – Take off protection cap of the headlight bulb. 600610-10 – Detach spring bar – Remove headlight bulb – Insert a new headlight bulb into the headlight housing. Headlight (H4 / socket P43t) ( p.

• Page 185: Changing The Parking Light Bulb

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

• Page 186: Changing The Turn Signal Bulb

  14 ELECTRICAL SYSTEM – Pull bulb socket out of the reflector. – Pull parking light bulb out of the bulb socket. – Insert a new parking light bulb in the bulb socket. Parking light (W5W / socket W2.1×9.5d) ( p. 247) –…

• Page 187
  ELECTRICAL SYSTEM 14 Main work – Remove the screw on the rear of the turn signal housing. – Tilt headlamp diffuser forward carefully and take it off. – Lightly squeeze orange cap in the area of the holding lugs and take it off. –…

• Page 188: Checking The Headlight Setting

  14 ELECTRICAL SYSTEM 14.12 Checking the headlight setting – Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight. – Make another mark at a distance under the first mark.

• Page 189: Adjusting The Headlight Range

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

• Page 190: Diagnostics Connector

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

• Page 191: Cooling System 15

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

• Page 192: Checking The Antifreeze And Coolant Level

  15 COOLING SYSTEM 15.2 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

• Page 193
  COOLING SYSTEM 15 – Stand the motorcycle on its side stand on a horizontal surface. – Remove the cover of compensating tank – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: –…
• Page 194
  15 COOLING SYSTEM – Remove radiator cap – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the speci- fied value: – Correct the antifreeze in the coolant. –…

• Page 195: Checking The Coolant Level

  COOLING SYSTEM 15 15.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

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

• Page 197: Draining The Coolant

  COOLING SYSTEM 15 15.4 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

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

• Page 199: Filling/Bleeding The Cooling System

  COOLING SYSTEM 15 15.5 Filling/bleeding the cooling system Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. –…

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

• Page 201: Changing The Coolant

  COOLING SYSTEM 15 – Check the coolant level. ( p. 193) 15.6 Changing the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

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

• Page 205: Tuning The Engine 16

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

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

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

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

  TUNING THE ENGINE 16 – Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the shift lever. Distance between shift lever 10 … 20 mm (0.39 … and upper edge of boot 0.79 in) 0 0 0 A »…

• Page 208
  16 TUNING THE ENGINE – Clean gear teeth of the shift lever and shift shaft. – Mount shift lever on the shift shaft in the required position and engage the gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure.

• Page 209: Service Work On The Engine 17

  SERVICE WORK ON THE ENGINE 17 17.1 Checking the engine oil level Info The engine oil level must be checked when the engine is warm. Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work –…

• Page 210: Changing The Engine Oil And Filter, Cleaning The Oil Screens

  17 SERVICE WORK ON THE ENGINE 17.2 Changing the engine oil and filter, cleaning the oil screens – Drain the engine oil. p. 208) – Remove the oil filter. p. 210) – Clean the oil screens. p. 211) – Install the oil filter. p.

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

• Page 212: Removing The Oil Filter

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

• Page 213: Cleaning The Oil Screens

  SERVICE WORK ON THE ENGINE 17 – Remove screws . Remove the oil filter cover with the O-ring. – Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) – Completely drain the engine oil. – Thoroughly clean the parts and sealing area. S02212-10 17.5 Cleaning the oil screens…

• Page 214
  17 SERVICE WORK ON THE ENGINE Main work – Remove screw plug with oil screen and the O-rings. S02213-10 – Remove screw plug with oil screen and the O-rings. – Completely drain the engine oil. – Thoroughly clean the parts and sealing surface. S02214-10…
• Page 215
  SERVICE WORK ON THE ENGINE 17 – Position oil screen with the O-rings. – Mount and tighten screw plug with the O-ring. Guideline Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) S02215-10 – Position oil screen with the O-rings. –…

• Page 216: Installing The Oil Filter

  17 SERVICE WORK ON THE ENGINE 17.6 Installing the oil filter – Insert oil filters – Oil the O-rings of the oil filter covers. Mount oil filter cov- – Mount and tighten the screws. Guideline Screw, oil filter cover 6 Nm (4.4 lbf ft) S02217-10 17.7 Filling up with engine oil…

• Page 217
  SERVICE WORK ON THE ENGINE 17 Main work – Remove filler plug with O-ring from the clutch cover and add engine oil. Engine oil 1.70 l Engine oil (1.8 qt.) (SAE 10W/60) (00062010035) p. 258) Engine oil Engine oil Alternative engine oil (SAE 10W/50) M00649-10 p.

• Page 218: Adding Engine Oil

  17 SERVICE WORK ON THE ENGINE – Check the engine oil level. ( p. 207) 17.8 Adding engine oil Info Too little engine oil or poor-quality engine oil results in premature wear of the engine. Main work – Remove filler plug and the O-ring from the clutch cover, and fill up with engine oil.

• Page 219
  SERVICE WORK ON THE ENGINE 17 Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space.

• Page 220: 18 Cleaning, Care

  18 CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –…

• Page 221
  CLEANING, CARE 18 – Seal the exhaust system to keep water out. – First remove coarse dirt particles with a gentle spray of water. – Spray very dirty areas with a normal motorcycle cleaner and then clean with a brush. Motorcycle cleaner ( p.
• Page 222
  18 CLEANING, CARE – After cleaning, ride a short distance until the engine reaches operating temperature. Info The heat produced causes water at inaccessible loca- tions in the engine and brake system to evaporate. – Push back the protection covers of the handlebar controls to allow any water that has penetrated to evaporate.

• Page 223: Checks And Maintenance Steps For Winter Operation

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

• Page 224
  18 CLEANING, CARE – Treat the engine, the swingarm, and all other bare or galvanized parts (except brake discs) with a wax-based anti-corrosion substance. Info To prevent serious reduction of the braking efficiency, make sure no anti-corrosion substance gets on to the brake discs.

• Page 225: Storage 19

  STORAGE 19 19.1 Storage Info If you want to garage the motorcycle for a longer period, take the following actions. Before storing the motorcycle, check all parts for function and wear. If service, repairs, or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season.

• Page 226
  19 STORAGE – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with a lift stand. ( p. 95) – Cover the motorcycle with a tarp or similar cover that is perme- able to air.

• Page 227: Preparing For Use After Storage

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

• Page 228: 20 Troubleshooting

  ( p. 176) – The plug-in connection of the Connect the plug-in connection of the fuel hose connection is not fuel line. connected – Defect in fuel injection system Read out the fault memory using the KTM diagnostics tool.

• Page 229
  Change fuel screen. – Fuel filter is very dirty Check the fuel pressure. – Defect in fuel injection system Read out the fault memory using the KTM diagnostics tool. – Map‑Select switch incorrectly Adjust the engine characteristic. adjusted p. 203) –…
• Page 230
  – Malfunction in ABS Read out the ABS fault memory using the KTM diagnostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary.
• Page 231
  TROUBLESHOOTING 20 Faults Possible cause Action – High oil consumption Engine oil too thin (low viscos- Change the engine oil and filter, clean ity) the oil screens. p. 208) – Headlight and parking light are Fuse 6 blown Change the fuses of individual power not functioning consumers.

• Page 232: 21 Blink Code

  21 BLINK CODE Blink code for malfunction indicator lamp 02 Malfunction indicator lamp flashes 2x short Error level condition Crankshaft position sensor — circuit fault Blink code for malfunction indicator lamp 09 Malfunction indicator lamp flashes 9x short Error level condition Manifold absolute pressure sensor cylinder 1 — input signal too low Manifold absolute pressure sensor cylinder 1 — input signal too high Blink code for malfunction…

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

• Page 239: Technical Data 22

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

• Page 240
  22 TECHNICAL DATA Clutch APTC™ antihopping clutch in oil bath/hydraulically operated Transmission 6-gear, claw shifted Transmission ratio 1st gear 14:35 2nd gear 16:28 3rd gear 21:28 4th gear 21:23 5th gear 23:22 6th gear 23:20 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment…

• Page 241: Engine Tightening Torques

  TECHNICAL DATA 22 22.2 Engine tightening torques Screw, membrane fixation 2 Nm (1.5 lbf ft) Loctite ® 243™ Hose clamp, intake flange 2.5 Nm (1.84 lbf ft) Oil nozzle for conrod bearing lubri- 2 Nm (1.5 lbf ft) Loctite ® 243™…

• Page 242
  22 TECHNICAL DATA Screw in alternator cover 10 Nm (7.4 lbf ft) Screw, alternator cover (chain 10 Nm (7.4 lbf ft) Loctite ® 243™ shaft through-hole) Screw, autodecompression 3 … 4 Nm (2.2 … 3 lbf ft) Loctite ® 243™ Screw, axial lock of camshaft 10 Nm (7.4 lbf ft) Loctite…
• Page 243
  TECHNICAL DATA 22 Screw, rocker arm shaft 12 Nm (8.9 lbf ft) Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, shift lever 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, starter motor 10 Nm (7.4 lbf ft) Loctite ®…
• Page 244
  22 TECHNICAL DATA Stud, exhaust flange 10 Nm (7.4 lbf ft) Loctite ® 243™ Cylinder head screw Tightening sequence: Tighten diagonally, beginning with the rear screw on the timing chain shaft. Step 1 15 Nm (11.1 lbf ft) Step 2 30 Nm (22.1 lbf ft) Step 3 45 Nm (33.2 lbf ft)
• Page 245
  TECHNICAL DATA 22 Spark plug inside M12x1.25 18 Nm (13.3 lbf ft) Coolant temperature sensor on M12x1.5 12 Nm (8.9 lbf ft) cylinder head Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) Oil pressure regulator valve plug M12x1.5 20 Nm (14.8 lbf ft) Screw plug, oil channel…

• Page 246: Capacities

  22 TECHNICAL DATA 22.3 Capacities 22.3.1 Engine oil Engine oil 1.70 l (1.8 qt.) Engine oil (SAE 10W/60) (00062010035) ( p. 258) Engine oil Engine oil (SAE 10W/50) Alternative engine oil p. 259) 22.3.2 Coolant Coolant 1.20 l (1.27 qt.) Coolant ( p.

• Page 247
  TECHNICAL DATA 22 Shock absorber WP Performance Systems 4618 with Pro‑Lever linkage Suspension travel front 250 mm (9.84 in) rear 250 mm (9.84 in) Brake system front Disc brake with dual-piston brake caliper, floating rear Disc brake with single-pot brake caliper, floating Brake discs — diameter front 300 mm (11.81 in)

• Page 248: Electrical System

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

• Page 249: Tires

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

• Page 250: Fork

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

• Page 251: Shock Absorber

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

• Page 252: Chassis Tightening Torques

  22 TECHNICAL DATA Hard 85 N/mm (485 lb/in) Spring length 220 mm (8.66 in) Gas pressure 10 bar (145 psi) Static sag 18 mm (0.71 in) Riding sag 70 … 80 mm (2.76 … 3.15 in) Fitted length 395 mm (15.55 in) Shock absorber fluid ( p.

• Page 253
  TECHNICAL DATA 22 Remaining screws, chassis 4 Nm (3 lbf ft) Screw, brake line holder on 4 Nm (3 lbf ft) swingarm Screw, cable on starter motor 3 Nm (2.2 lbf ft) Screw, combination switch, left 3.5 Nm (2.58 lbf ft) Screw, electrical holder 3 Nm (2.2 lbf ft) Screw, exhaust heat shield…
• Page 254
  22 TECHNICAL DATA Screw, ABS control unit 5 Nm (3.7 lbf ft) Screw, ABS module retaining 10 Nm (7.4 lbf ft) bracket on frame Screw, air filter box top 2 Nm (1.5 lbf ft) Screw, ball joint of push rod on 10 Nm (7.4 lbf ft) Loctite ®…
• Page 255
  TECHNICAL DATA 22 Screw, magnetic holder on side 6 Nm (4.4 lbf ft) Loctite ® 243™ stand Screw, radiator bleeding 8 Nm (5.9 lbf ft) Screw, radiator guard 8 Nm (5.9 lbf ft) Screw, rear brake disc 14 Nm (10.3 lbf ft) Loctite ®…
• Page 256
  22 TECHNICAL DATA Screw, fork stub 15 Nm (11.1 lbf ft) Screw, front brake caliper 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, front footrest bracket 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, fuel tank bracket 15 Nm (11.1 lbf ft) Screw, fuel tank, bottom 25 Nm (18.4 lbf ft) Loctite…
• Page 257
  TECHNICAL DATA 22 Screw, spring holder on side stand 25 Nm (18.4 lbf ft) Loctite ® 243™ bracket Screw, steering stem 20 Nm (14.8 lbf ft) Screw, top triple clamp 17 Nm (12.5 lbf ft) Engine carrying screw 45 Nm (33.2 lbf ft) Loctite ®…
• Page 258
  22 TECHNICAL DATA Screw, radiator temperature sensor 20 Nm (14.8 lbf ft) Screw, bottom steering head M20x1.5 60 Nm (44.3 lbf ft) Loctite ® 243™ Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) Nut, rear wheel spindle M25x1.5…

• Page 259: Substances 23

  SUBSTANCES 23 Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 Motorex ®…

• Page 260
  JASO T903 MA ( p. 263) – SAE ( p. 263) (SAE 10W/60) – KTM LC4 2007+ Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Synthetic engine oil…
• Page 261
  SUBSTANCES 23 Engine oil (SAE 10W/50) Standard/classification – JASO T903 MA ( p. 263) – SAE ( p. 263) (SAE 10W/50) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties.
• Page 262
  23 SUBSTANCES Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification – DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline –…

• Page 263: Auxiliary Substances 24

  AUXILIARY SUBSTANCES 24 Chain cleaner Recommended supplier Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Long-life grease Recommended supplier Motorex ® – Bike Grease 2000 Motorcycle cleaner Recommended supplier Motorex ® – Moto Clean Off-road chain spray Recommended supplier Motorex…

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

• Page 265: Standards 25

  STANDARDS 25 JASO T903 MA Different technical development directions required a separate specification for motorcycles – the JASO T903 MA standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

• Page 266: 26 Index Of Special Terms

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

• Page 267: List Of Abbreviations 27

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

• Page 268: 28 List Of Symbols

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

• Page 269: Green And Blue Symbols

  LIST OF SYMBOLS 28 28.3 Green and blue symbols Green and blue symbols reflect information. Turn signal indicator lamp flashes green – The turn signal is switched on. The idle indicator lamp lights up green – The transmission is in idle. The high beam indicator lamp lights up blue –…

• Page 270: Index

  INDEX Brake fluid level INDEX checking the brake fluid level of front brake . 126 ABS ……. 122 rear brake, checking .

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

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