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• Page 1
  OWNER’S MANUAL 2016 690 SMC R Art. no. 3213394en…
• Page 3
  KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.
• Page 4
  Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.

• Page 5: Table Of Contents

  TABLE OF CONTENTS Shock absorber article number ……22 TABLE OF CONTENTS MEANS OF REPRESENTATION ……..7 CONTROLS…………..23 Symbols used …………7 Clutch lever…………23 Formats used…………8 Hand brake lever……….23 SAFETY ADVICE………….. 9 Throttle grip …………24 Use definition — intended use ……..

• Page 6
  TABLE OF CONTENTS 6.13 Seat release …………38 10.6 Adjusting the high-speed compression damping of the shock absorber ……… 65 6.14 Handrails …………38 10.7 Adjusting the rebound damping of the shock 6.15 Passenger footrests ……….39 absorber…………66 6.16 Shift lever …………
• Page 7
  TABLE OF CONTENTS 11.19 Adjusting the basic position of the clutch lever ..86 14.3 Recharging the battery ……..117 11.20 Checking/rectifying the fluid level of the 14.4 Changing the main fuse ……..120 hydraulic clutch……….87 14.5 Changing the ABS fuses ……..121 12 BRAKE SYSTEM …………
• Page 8
  TABLE OF CONTENTS 17.4 Removing the oil filter ……..146 25 STANDARDS ………….. 188 17.5 Cleaning the oil screens …….. 148 26 INDEX OF SPECIAL TERMS ……… 189 17.6 Installing the oil filter ……..150 27 LIST OF ABBREVIATIONS……….190 17.7 Filling up with engine oil …….

• Page 9: Means Of Representation

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

• Page 10: Formats Used

  MEANS OF REPRESENTATION Formats used The typographical formats used in this document are explained below. Specific name Identifies a proprietary name. Name ® Identifies a protected name. Brand™ Identifies a brand available on the open market. Underlined terms Refer to technical details of the vehicle or indicate technical terms that are explained in the glossary.

• Page 11: Safety Advice

  SAFETY ADVICE Use definition — intended use KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race courses or offroad. Info The motorcycle is only authorized for operation on public roads in the homologated version.

• Page 12: Degrees Of Risk And Symbols

  SAFETY ADVICE Degrees of risk and symbols Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.

• Page 13: Safe Operation

  Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. An appropriate driver’s license is needed to ride the vehicle on public roads. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.

• Page 14: Protective Clothing

  Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements. 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.

• Page 15: Owner’s Manual

  Keep the Owner’s Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.

• Page 16: Important Notes

  Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the warranty.

• Page 17: Service

  Please follow the instructions in the text. Customer service Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM. A list of authorized KTM dealers can be found on the KTM website.

• Page 18: View Of Vehicle

  VIEW OF VEHICLE View of vehicle, front left side (example) 101971-10…

• Page 19
  VIEW OF VEHICLE Hand brake lever ( p. 23) Clutch lever ( p. 23) Handrails ( p. 38) Filler cap Engine number ( p. 21) Shift lever ( p. 39) Side stand ( p. 41) Seat release ( p. 38) Compression damping of the shock absorber ( p.

• Page 20: View Of Vehicle, Rear Right Side (Example)

  VIEW OF VEHICLE View of vehicle, rear right side (example) 101972-10…

• Page 21
  VIEW OF VEHICLE Ignition/steering lock ( p. 27) Fork compression adjustment Light switch ( p. 25) Turn signal switch ( p. 25) Horn button ( p. 24) Function buttons ( p. 28) Indicator lamps ( p. 29) Emergency OFF switch ( p.

• Page 22: Serial Numbers

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

• Page 23: Key Number

  SERIAL NUMBERS Key number  can be found on the KEYCODECARD. The key number Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place. 402241-10 Engine number  The engine number is stamped on the left side of the engine under the engine sprocket. 401949-10…

• Page 24: Fork Part Number

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

• Page 25: Controls

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

• Page 26: Throttle Grip

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

• Page 27: Light Switch

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

• Page 28: Emergency Off Switch

  CONTROLS Emergency OFF switch  The emergency OFF switch is fitted on the right side of the handlebar. Possible states Emergency OFF switch off – In this position, the ignition circuit is inter- rupted, a running engine stops, and the engine cannot be started. Emergency OFF switch on –…

• Page 29: Ignition/Steering Lock

  CONTROLS Ignition/steering lock  The ignition/steering lock is located in front of the seat. Possible states Ignition OFF – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. The ignition key can be removed.

• Page 30: Function Buttons

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

• Page 31: Indicator Lamps

  CONTROLS 6.10.4 Indicator lamps The indicator lamps offer additional information about the operating state of the motorcy- cle. Possible states The turn signal indicator lamp flashes green simultaneously with the turn signal – The turn signal is switched on. The idling speed indicator lamp lights up green – The transmission is shifted to idle.

• Page 32: Display

  CONTROLS 6.10.5 Display When the ignition is switched on, all display segments light up for one second as a function check. 400836-01 LEnGth After the display function check, the wheel circumference LEnGth is displayed for one sec- ond. Info The number 1870 mm equals the circumference of the 17″ front wheel with a series production tire.

• Page 33: Speed Display

  CONTROLS 6.10.6 Speed display  The speed is shown in kilometers per hour km/h or in miles per hour mph. 401443-10 6.10.7 Setting the kilometers or miles Info If the unit is changed, the value is retained and converted accordingly. Make the setting according to the country.

• Page 34: Time

  CONTROLS – Switch on the ignition by turning the ignition key to position ON – Press the MODE button repeatedly until the ODO display mode is active. – Keep the MODE button pressed until the display mode changes from km/h to mph or from mph to km/h.

• Page 35: 6.10.10 Odo Display

  CONTROLS – Switch on the ignition by turning the ignition key to position ON – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button and the SET button pressed simultaneously. The time display begins to flash. –…

• Page 36: Setting/Resetting Display Trip 2

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

• Page 37: 6.10.13 Trip F Display

  CONTROLS 6.10.13 TRIP F display If the fuel level drops to the reserve mark, the display automatically changes to TRIP F and starts to count from 0.0, regardless of the previous display mode. Info The low fuel warning lamp lights up in parallel to the TRIP F display. 401447-01 6.10.14 GEAr display In display mode GEAr, the gear currently engaged is displayed.

• Page 38: 6.10.15 Coolant Temperature Indicator

  CONTROLS 6.10.15 Coolant temperature indicator The temperature display consists of 12 bars. The more bars that light up, the hotter the coolant. When the upper bar lights up, all bars in the display begin to flash and the temper- ature warning lamp lights up. Possible states Engine cold –…

• Page 39: Closing Filler Cap

  CONTROLS Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. –  Lift cover of filler cap and insert the ignition key. –…

• Page 40: Seat Release

  CONTROLS 6.13 Seat release  The seat can be released using strap 101977-10 6.14 Handrails  The handrails are used for moving the motorcycle around. When you have a passenger, the passenger can hold on the handrails during the journey. 101978-10…

• Page 41: Passenger Footrests

  CONTROLS 6.15 Passenger footrests The passenger footrests can be folded up and down. Possible states Passenger footrests folded up – For operation without a passenger. • Passenger footrests folded down – For operation with a passenger. • 101979-01 6.16 Shift lever …

• Page 42: Foot Brake Lever

  CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 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…

• Page 43: Side Stand

  CONTROLS 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. Info The side stand must be folded up during motorcycle use. The side stand is coupled with the safety starting system – see the riding instruc- tions.

• Page 44: Preparing For Use

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

• Page 45: Running In The Engine

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

• Page 46: Loading The Vehicle

  PREPARING FOR USE – Avoid fully opening the throttle! Loading the vehicle Warning Danger of accidents Unstable handling characteristics. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage. Warning Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack.

• Page 47
  PREPARING FOR USE Warning Danger of accidents Unstable handling characteristics due to slipped baggage. – Check the way your baggage is fixed regularly. Warning Danger of burns A hot exhaust system can burn baggage. – Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system. –…

• Page 48: Riding Instructions

  RIDING INSTRUCTIONS Performing checks and vehicle care when preparing for use Info Before each use, check the state and roadworthiness of the vehicle. Make sure that the vehicle is in perfect technical condition before use. – Check the engine oil level. ( p.

• Page 49: Starting

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

• Page 50
  Take the weight off the side stand and swing it back up with your foot as far as it will Switching off ABS KTM recommends riding with ABS at all times. However, situations may arise in which ABS is not advantageous.

• Page 51: Starting Off

  RIDING INSTRUCTIONS Starting off – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully. Shifting, riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control. –…

• Page 52
  RIDING INSTRUCTIONS Warning Danger of accidents Reduced road grip with cold tires. – On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured. Warning Danger of accidents Reduced road grip with new tires. –…
• Page 53
  Info If unusual noises arise during operation, stop immediately, switch off the engine, park the vehicle properly, and contact an autho- rized KTM workshop. – Shift into a higher gear when conditions allow (incline, road situation, etc.). –…

• Page 54: Applying The Brakes

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

• Page 55
  RIDING INSTRUCTIONS Warning Danger of accidents Longer stopping distance due to higher overall weight. – Take the longer stopping distance into account when carrying a passenger and baggage. Warning Danger of accidents Delayed brake action on salted roads. – There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the deposits from the discs by carefully applying the brakes.

• Page 56: Stopping, Parking

  RIDING INSTRUCTIONS Warning Danger of accidents Road grip is reduced when braking with the motorcycle at an angle or on a laterally inclined surface. – Braking should be completed before you enter into a bend. – Always finish braking before you go into a bend. Change down to a lower gear appropriate to your road speed. –…

• Page 57: Transport

  RIDING INSTRUCTIONS Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run.

• Page 58: Refueling

  RIDING INSTRUCTIONS Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run.

• Page 59
  – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards.
• Page 60
  RIDING INSTRUCTIONS – Press the SET button  for two seconds.  The fuel level warning lamp switches off. TRIP F is set to 0.0 and the display returns to the previous display mode. Info  If you do not press the SET button , the reset takes place automatically after approx.

• Page 61: Service Schedule

  ○ ● ● Check that the electrical equipment is functioning correctly. ○ ● ● Read out the fault memory using the KTM diagnostics tool. ● ● Check the measured service values with the KTM diagnostics tool. ○ ● ● Change the engine oil and filter, clean the oil screens.

• Page 62
  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 the KTM Dealer.net and in the Service and Warranty Booklet.
• Page 63
  SERVICE SCHEDULE ○ One-time interval ● Periodic interval…

• Page 64: Tuning The Chassis

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

• Page 65: Adjusting The Rebound Damping Of The Fork

  TUNING THE CHASSIS Guideline Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 10.3 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. –…

• Page 66: Compression Damping Of The Shock Absorber

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

• Page 67: Adjusting The High-Speed Compression Damping Of The Shock Absorber

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

• Page 68: Adjusting The Rebound Damping Of The Shock Absorber

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

• Page 69: Handlebar Position

  TUNING THE CHASSIS – Turn adjusting screw  clockwise up to the last perceptible click. – Turn counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks 601891-10 Full payload 10 clicks…

• Page 70: Adjusting The Handlebar Position

  TUNING THE CHASSIS 10.9 Adjusting the handlebar position –  Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against damage. Do not kink the cables and lines. –…

• Page 71: Service Work On The Chassis

  SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle in the area of the footrest bracket. Lift stand (78929955100) Neither wheel is in contact with the ground.

• Page 72: Raising The Motorcycle With The Rear Wheel Stand

  SERVICE WORK ON THE CHASSIS – Remove the motorcycle from the lift stand and rest it on side stand  – Remove the lift stand. 401943-10 11.3 Raising the motorcycle with the rear wheel stand Note Danger of damage The parked vehicle may roll away or fall over. –…

• Page 73: Removing The Rear Of The Motorcycle From The Wheel Stand

  SERVICE WORK ON THE CHASSIS 11.4 Removing the rear of the motorcycle from the wheel stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Secure the motorcycle against falling over.

• Page 74: Taking The Motorcycle Off Of The Front Wheel Stand

  SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Align the front wheel stand with the fork legs using the adapters. Front wheel stand (61029055300) Info Always raise the rear of the motorcycle first. –…

• Page 75
  SERVICE WORK ON THE CHASSIS Main work –  Push dust boots of both fork legs downward. Info The dust boots remove dust and coarse dirt particles from the inside fork tubes. Over time, dirt can accumulate behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak.

• Page 76: Removing The Fork Protector

  SERVICE WORK ON THE CHASSIS 11.8 Removing the fork protector –  Remove screws and take off clamp. –  Remove screws on left fork leg. Remove the fork protector. – Remove the screws on the right fork leg. Remove the fork protector. 101986-10 11.9 Installing the fork protector…

• Page 77: Removing The Seat

  SERVICE WORK ON THE CHASSIS 11.10 Removing the seat –  Pull on strap and raise the rear of the seat at the same time. – Pull back the seat and lift it off. 101977-10 11.11 Mounting the seat 101988-10 –…

• Page 78: Removing The Air Filter

  SERVICE WORK ON THE CHASSIS 11.12 Removing the air filter Preparatory work – Remove the seat. ( p. 75) Main work –   Remove screws . Take off air filter box top 601882-10 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine.

• Page 79: Installing The Air Filter

  SERVICE WORK ON THE CHASSIS 11.13 Installing the air filter Main work – Clean the air filter box. –  Mount air filter Info The air filter must lie flush against the air filter box along the entire sealing sur- face …

• Page 80: Checking The Chain For Dirt

  SERVICE WORK ON THE CHASSIS 11.14 Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 78) 400678-01 11.15 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. –…

• Page 81: Checking The Chain Tension

  SERVICE WORK ON THE CHASSIS Info The service life of the chain depends largely on its maintenance. Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 70) Main work – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. –…

• Page 82
  SERVICE WORK ON THE CHASSIS – Lean the motorcycle on the side stand. – Shift gear to neutral. –  Push the chain upward at a distance from the chain sliding guard and determine  the chain tension Info  The upper chain section must be taut.

• Page 83: Adjusting The Chain Tension

  SERVICE WORK ON THE CHASSIS 11.17 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bearings in the transmission and in the rear wheel) will be under additional load.

• Page 84: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

  SERVICE WORK ON THE CHASSIS Main work –  Loosen nut – Loosen nuts  –  Adjust the chain tension by turning adjusting screws on the left and right. Guideline Chain tension 5 mm (0.2 in)  Turn adjusting screws on the left and right so that the markings on the left and …

• Page 85
  SERVICE WORK ON THE CHASSIS Main work – Shift the transmission to idle. – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket or engine sprocket is worn: – Change the power set. Info The engine sprocket, rear sprocket, and chain should always be replaced together.
• Page 86
  SERVICE WORK ON THE CHASSIS Info When the chain is replaced, the rear sprocket and engine sprocket should also be changed. New chains wear out faster on an old, worn rear sprocket or engine sprocket. – Check the chain sliding guard for wear. »…
• Page 87
  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 88: Adjusting The Basic Position Of The Clutch Lever

  SERVICE WORK ON THE CHASSIS – Check that the chain guide is firmly seated. » If the chain guide is loose: – Tighten the screws on the chain guide. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 601884-01 Finishing work –…

• Page 89: Checking/Rectifying The Fluid Level Of The Hydraulic Clutch

  SERVICE WORK ON THE CHASSIS – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw  – When adjusting the clutch lever, make sure to leave a minimum clearance to other parts of the vehicle. Guideline Minimum clearance 5 mm (0.2 in)

• Page 90: Brake System

  KTM. – Service work and repairs must be performed properly. (Your authorized KTM workshop will be glad to help.) The ABS is a safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces.

• Page 91: Adjusting The Basic Position Of The Hand Brake Lever

  BRAKE SYSTEM the brake pressure. The regulating process causes a slight pulsing of the hand and foot brake levers.  ABS warning lamp must light up after the ignition is switched on and go out after start- ing off. If it does not go out after starting off or if it lights up while riding, this indicates a fault in the ABS system.

• Page 92: Checking The Brake Discs

  Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs in several places to ensure that it …

• Page 93: Checking The Front Brake Fluid Level

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

• Page 94
  Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

• Page 95: Checking The Front Brake Linings

  Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. –…

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

  BRAKE SYSTEM – Check the brake linings for minimum thickness  ≥ 1 mm (≥ 0.04 in)  Minimum thickness » If the minimum thickness is less than specified: – Change the brake linings of the front brake. – Check the brake linings for damage and cracking. »…

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

  BRAKE SYSTEM 12.8 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 over- heating.

• Page 98: Checking Rear Brake Fluid Level

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

• Page 99
  Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

• Page 100: Checking The Rear Brake Linings

  Checking the rear brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) Note Danger of accidents Reduced braking efficiency caused by damaged brake discs. –…

• Page 101
  BRAKE SYSTEM – Check the brake linings for minimum thickness  ≥ 1 mm (≥ 0.04 in)  Minimum thickness » If the minimum thickness is less than specified: – Change the rear brake linings. – Check the brake linings for damage and cracking. »…

• Page 102: Wheels, Tires

  WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 70) – Raise the motorcycle with the front wheel stand. ( p. 71) Main work –   Remove screw and pull wheel speed sensor out of the hole.

• Page 103: Installing The Front Wheel

  WHEELS, TIRES – Remove spacers  H00934-12 13.2 Installing the front wheel 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. Main work –…

• Page 104
  WHEELS, TIRES – Lift the front wheel into the fork, position it, and insert the wheel spindle. –  Mount and tighten screw Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) –   Position the wheel speed sensor in the drill hole.

• Page 105: Removing The Rear Wheel

  WHEELS, TIRES – Take the motorcycle off of the front wheel stand. ( p. 72) – Operate the front brake and compress the fork a few times firmly. The fork legs straighten. –  Tighten screws Guideline Screw, fork stub 15 Nm (11.1 lbf ft) 101999-10…

• Page 106: Installing The Rear Wheel

  WHEELS, TIRES – Pull out wheel spindle  to the point where the chain adjuster is no longer in contact with the adjusting screw. – Push the rear wheel forward as far as possible and take the chain off the rear sprocket. Info Cover the components to protect them against damage.

• Page 107
  WHEELS, TIRES Main work – Check the rear hub rubber dampers. p. 106) – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Replace the wheel bearing. – Remove spacer. – …

• Page 108: Checking The Rear Hub Rubber Dampers

  WHEELS, TIRES – Push the rear wheel forward as far as possible and lay the chain on the rear sprocket. –    Mount wheel spindle and chain adjuster . Mount nut , but do not tighten it yet. –…

• Page 109
  WHEELS, TIRES Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 70) – Remove the rear wheel. p. 103) Main work –  Check bearing » If the bearing is damaged or worn: – Replace the bearings. –…

• Page 110: Checking The Tire Condition

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

• Page 111
  DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture. KTM recommends that the tires are changed regardless of the actual wear, at the latest after 5 years.

• Page 112: Tubeless Tire System

  This results in better handling and riding comfort. The rigid rim design results in a spoke wheel that is almost entirely maintenance-free. KTM recommends that the tubeless sealing profile be changed after 5 years at the latest, regardless of the actual state of wear.

• Page 113: Checking The Spoke Tension

  Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes.

• Page 114
  WHEELS, TIRES – Briefly strike each spoke with a screwdriver blade. Info The frequency of the tone is a function of the spoke length and spoke diameter. If you hear different tone frequencies from individual spokes of the same length and thickness, this is an indication of different spoke tensions.

• Page 115: Electrical System

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

• Page 116
  ELECTRICAL SYSTEM – Disconnect negative cable  from the battery. –  Take off the positive terminal cover S00622-10 –   Disconnect the ABS connection cable and positive cable from the battery. S00620-10 –  Remove screws –  Pull retaining bracket of the battery forward and remove it.

• Page 117: Installing The Battery

  ELECTRICAL SYSTEM 14.2 Installing the battery Main work – Insert the battery into the battery compartment with the terminals facing rearward. Battery (YTZ10S) ( p. 175) –   Position retaining bracket and mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) S00621-11 –…

• Page 118
  ELECTRICAL SYSTEM – Position positive terminal cover  –   Position washer and negative cable , and mount and tighten the screw. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) S00622-11 –  Position EFI control unit – …

• Page 119: Recharging The Battery

  – Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly 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 120
  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 121
  ELECTRICAL SYSTEM Main work – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the bat- tery, and to test the alternator. With this device, you cannot overcharge the battery. Info …

• Page 122: Changing The Main Fuse

  ELECTRICAL SYSTEM 14.4 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 bypass 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 123: Changing The Abs Fuses

  ELECTRICAL SYSTEM – Remove a defective main fuse  with needle nose pliers. Info  A defective fuse is indicated by a burned-out fuse wire  A reserve fuse is located in the starter relay. – Install a new main fuse. Fuse (58011109130) ( p.

• Page 124
  ELECTRICAL SYSTEM Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. ( p. 75) – Remove the battery cover. – Pull the EFI control unit off of the holder and set it to one side. To change the fuse of the ABS hydraulic unit: –…

• Page 125: Changing The Fuses Of Individual Power Consumers

  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 all power consumers and switch off the engine. – Remove the seat.

• Page 126
  ELECTRICAL SYSTEM – Remove the defective fuse. Guideline Fuse 1 — 10 A — ignition, combination instrument, clock, EFI control unit Fuse 2 — 10 A — ignition, combination instrument, EFI control unit Fuse 3 — 10 A — fuel pump Fuse 4 — 10 A — radiator fan Fuse 5 — 10 A — horn, brake light, turn signal Fuse 6 — 15 A — high beam, low beam, parking light, tail light, license plate lamp…

• Page 127: Removing The Headlight Mask With The Headlight

  ELECTRICAL SYSTEM Replace the spare fuse in the fuse box so that it is available if needed. – Check that the power consumer is functioning properly. – Close the fuse box cover. Finishing work – Mount the seat. ( p. 75) 14.7 Removing the headlight mask with the headlight Preparatory work…

• Page 128: Installing The Headlight Mask With The Headlight

  ELECTRICAL SYSTEM – Disconnect plug-in connectors  for the turn signals and  for the headlight. – Remove the headlight mask. 102026-10 14.8 Installing the headlight mask with the headlight Main work –   Connect plug-in connectors of the headlight and of the turn signals.

• Page 129
  ELECTRICAL SYSTEM – Remove the cloth from the fender and position the headlight mask.  Holding lugs engage in the headlight mask. 102027-10 –   Position groove on counterpiece 102028-10 –   Position brake line guides . Mount and tighten screws Guideline Screw, headlight mask 5 Nm (3.7 lbf ft)

• Page 130: Changing The Headlight Bulb

  ELECTRICAL SYSTEM Finishing work – Check the headlight setting. ( p. 132) 14.9 Changing the headlight bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.

• Page 131: Changing The Parking Light Bulb

  ELECTRICAL SYSTEM – Detach spring bar  –  Remove headlight bulb – Insert a new headlight bulb into the headlight housing. Headlight (H4 / socket P43t) ( p. 176) – Fix the headlight bulb in the headlight using the spring bar. –…

• Page 132
  ELECTRICAL SYSTEM Main work –  Remove protection cap 600610-12 –  Pull bulb socket out of the reflector. –  Pull parking light bulb out of the bulb socket. – Insert a new parking light bulb in the bulb socket. Parking light (W5W / socket W2.1×9.5d) ( p.

• Page 133: Changing The Turn Signal Bulb

  ELECTRICAL SYSTEM 14.11 Changing the turn signal bulb Note Damage to reflector Reduced brightness. – Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.

• Page 134: Checking The Headlight Setting

  ELECTRICAL SYSTEM 14.12 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 135
  ELECTRICAL SYSTEM Main work –  Turn adjusting screw to adjust the headlight range. Guideline The boundary between light and dark must be exactly on the lower mark for a motor- cycle with a rider (instructions on how to apply the mark: Checking the headlight set- ting).

• Page 136: Cooling System

  COOLING SYSTEM 15.1 Cooling system  The water pump in the engine forces the coolant to flow. The pressure in the cooling system resulting from heat is regulated by a valve in the radia-  tor cap . The heat expansion causes the surplus coolant to flow into the compensating tank …

• Page 137
  COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immedi- ately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, con- tact a physician immediately.

• Page 138: Checking The Coolant Level

  COOLING SYSTEM – Screw off the radiator cap  – Check antifreeze of coolant. −25… −45 °C (−13… −49 °F) » If the antifreeze of the coolant does not meet specifications: – Correct the antifreeze of the coolant. – Check the coolant level in the radiator. The radiator must be completely filled.

• Page 139: Draining The Coolant

  COOLING SYSTEM Condition Engine is cold. – Stand the motorcycle on its side stand on a horizontal surface. –  Check the coolant level in the compensating tank The coolant level must be within the range shown in the figure. »…

• Page 140: Filling/Bleeding The Cooling System

  COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immedi- ately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, con- tact a physician immediately.

• Page 141
  COOLING SYSTEM – Stand the motorcycle on its side stand on a horizontal surface. –  Remove radiator cap 102015-11 – Refill the coolant. Coolant ( p. 183) –  Fill the radiator completely with coolant. Mount radiator cap 102017-10 –…
• Page 142
  COOLING SYSTEM Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

• Page 143: Tuning The Engine

  TUNING THE ENGINE 16.1 Adjusting the engine characteristic Preparatory work – Switch off the ignition by turning the ignition key to position OFF – Remove the seat. ( p. 75) Main work –  Pull the Map‑Select switch and holder upward off of the retaining bracket.

• Page 144: Checking The Basic Position Of The Shift Lever

  TUNING THE ENGINE – Position the Map‑Select switch in the holder. – Slide the Map‑Select switch with the holder downward onto the retaining bracket. Finishing work – Mount the seat. ( p. 75) 16.2 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider’s boot when in the basic position.

• Page 145: Adjusting The Basic Position Of The Shift Lever

  TUNING THE ENGINE 16.3 Adjusting the basic position of the shift lever –   Remove screw with washers and take off shift lever 401950-12 –  Clean gear teeth of the shift lever and shift shaft. –  Mount shift lever on the shift shaft in the required position and engage the gearing.

• Page 146: Service Work On The Engine

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

• Page 147: Changing The Engine Oil And Filter, Cleaning The Oil Screens

  SERVICE WORK ON THE ENGINE 17.2 Changing the engine oil and filter, cleaning the oil screens – Drain the engine oil. p. 145) – Remove the oil filter. p. 146) – Clean the oil screens. p. 148) – Install the oil filter. p.

• Page 148: Removing The Oil Filter

  SERVICE WORK ON THE ENGINE – Place a suitable container under the engine. –  Remove oil drain plug with the magnet and seal ring. – Completely drain the engine oil. 100200-10 – Thoroughly clean the oil drain plug with magnet. –…

• Page 149
  SERVICE WORK ON THE ENGINE Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Preparatory work – Place a suitable container under the engine. Main work –…

• Page 150: Cleaning The Oil Screens

  SERVICE WORK ON THE ENGINE 17.5 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 151
  SERVICE WORK ON THE ENGINE – Remove screw plug  with oil screen  and the O-rings. – Completely drain the engine oil. – Thoroughly clean the parts and sealing area. 100206-10 –  Position oil screen with the O-rings. –…

• Page 152: Installing The Oil Filter

  SERVICE WORK ON THE ENGINE 17.6 Installing the oil filter –   Insert oil filters –   Oil the O-rings of the oil filter covers. Mount oil filter covers – Mount and tighten the screws. Guideline Screw, oil filter cover M5x16 6 Nm (4.4 lbf ft) 102022-10…

• Page 153: Adding Engine Oil

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

• Page 154
  SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

• Page 155: Cleaning, Care

  CLEANING, CARE 18.1 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 pres- sure can cause malfunctions or destroy these parts.

• Page 156
  CLEANING, CARE – After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly. – Remove the plug from the exhaust system. Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake sys- tem.

• Page 157: Checks And Maintenance Steps For Winter Operation

  CLEANING, CARE Special cleaner for glossy and matte paint finishes, metal and plastic surfaces p. 187) – Lubricate the ignition/steering lock. Universal oil spray ( p. 187) 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 precautions against aggressive road salt.

• Page 158
  CLEANING, CARE – Clean the chain. ( p. 78)

• Page 159: Storage

  STORAGE 19.1 Storage Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water.

• Page 160
  – Store the vehicle in a dry location that is not subject to large fluctuations in tempera- ture. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with the rear wheel stand. ( p. 70) –…

• Page 161: Preparing For Use After Storage

  STORAGE 19.2 Preparing for use after storage – Take the motorcycle off of the front wheel stand. ( p. 72) – Remove the rear of the motorcycle from the wheel stand. ( p. 71) – Recharge the battery. p. 117) –…

• Page 162: Troubleshooting

  Connect the plug-in connection of the fuel line. connection is not connected – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine has too little power. Air filter is very dirty Remove the air filter.

• Page 163
  Air in cooling system Fill/bleed the cooling system. p. 138) – FI warning lamp (MIL) lights/flashes Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine dies during the journey Lack of fuel Refuel. ( p.
• Page 164
  TROUBLESHOOTING Faults Possible cause Action – High oil consumption Engine oil too thin (low viscosity) Change the engine oil and filter, clean the oil screens. p. 145) – Headlight and parking light are not Fuse 6 blown Change the fuses of individual power consumers. functioning p.

• Page 165: Blink Code

  BLINK CODE Blink code FI of warning lamp (MIL) 02 FI warning lamp (MIL) flashes briefly 2x Error level condition Crankshaft position sensor — circuit fault Blink code FI of warning lamp (MIL) 09 FI warning lamp (MIL) flashes briefly 9x Error level condition Manifold absolute pressure sensor cylinder 1 — input signal too low Manifold absolute pressure sensor cylinder 1 — input signal too high…

• Page 166
  BLINK CODE Blink code FI of warning lamp (MIL) 15 FI warning lamp (MIL) flashes 1x long, 5x short Error level condition Rollover sensor — input signal too low Rollover sensor — input signal too high Blink code FI of warning lamp (MIL) 17 FI warning lamp (MIL) flashes 1x long, 7x short Error level condition…
• Page 167
  BLINK CODE Blink code FI of warning lamp (MIL) 27 FI warning lamp (MIL) flashes 2x long, 7x short Error level condition Accelerator position sensor circuit fault — accelerator position sensor voltage Blink code FI of warning lamp (MIL) 33 FI warning lamp (MIL) flashes 3x long, 3x short Error level condition Injector cylinder 1 — circuit fault Blink code FI of warning lamp…
• Page 168
  BLINK CODE Blink code FI of warning lamp (MIL) 45 FI warning lamp (MIL) flashes 4x long, 5x short Error level condition Lambda sensor heater cylinder 1, sensor 1 — short circuit to ground or open circuit Lambda sensor heater cylinder 1, sensor 1 — input signal too high Blink code FI of warning lamp (MIL) 65 FI warning lamp (MIL) flashes 6x long, 5x short…
• Page 169
  BLINK CODE Blink code FI of warning lamp (MIL) 85 FI warning lamp (MIL) flashes 8x long, 5x short Error level condition Accelerator position sensor circuit A — input signal too low Accelerator position sensor circuit A — input signal too high Blink code FI of warning lamp (MIL) 86 FI warning lamp (MIL) flashes 8x long, 6x short…
• Page 170
  BLINK CODE Blink code FI of warning lamp (MIL) 92 FI warning lamp (MIL) flashes 9x long, 2x short Error level condition DBW throttle actuator control IC — stuck open Blink code FI of warning lamp (MIL) 93 FI warning lamp (MIL) flashes 9x long, 3x short Error level condition CPU mutual — surveillance error Blink code FI of warning lamp…

• Page 171: Technical Data

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

• Page 172: Engine Tightening Torques

  TECHNICAL DATA 3rd gear 21:28 4th gear 21:23 5th gear 23:22 6th gear 23:20 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Alternator 12 V, 224 W Spark plug Inside spark plug NGK LKAR8BI-9 Outside spark plug NGK LMAR7A-9 Spark plug electrode gap…

• Page 173
  TECHNICAL DATA Screw, gear position sensor M5x16 5 Nm (3.7 lbf ft) Loctite ® 243™ – Screw, oil filter cover M5x16 6 Nm (4.4 lbf ft) Screw, oil pump cover, top 6 Nm (4.4 lbf ft) Loctite ® 243™ Loctite ®…
• Page 174
  TECHNICAL DATA Screw, thermostat case M6x20 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, timing chain guide rail M6x30 10 Nm (7.4 lbf ft) Loctite ® 2701™ Screw, timing chain tensioning rail M6x30 10 Nm (7.4 lbf ft) Loctite ®…

• Page 175: Capacities

  TECHNICAL DATA – Screw, unlocking of timing chain ten- M10x1 10 Nm (7.4 lbf ft) sioner – Spark plug outside M10x1 11 Nm (8.1 lbf ft) – Spark plug inside M12x1.25 18 Nm (13.3 lbf ft) – Coolant temperature sensor on cylinder M12x1.5 12 Nm (8.9 lbf ft) head…

• Page 176: Coolant

  TECHNICAL DATA 22.3.2 Coolant Coolant 1.20 l (1.27 qt.) Coolant ( p. 183) 22.3.3 Fuel Total fuel tank capacity, approx. 12 l (3.2 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 185) Fuel reserve, approx. 2.5 l (2.6 qt.) 22.4 Chassis Frame…

• Page 177: Electrical System

  TECHNICAL DATA Rear 4.5 mm (0.177 in) Tire air pressure, solo Front 2.0 bar (29 psi) Rear 2.0 bar (29 psi) Tire air pressure with passenger / fully loaded Front 2.0 bar (29 psi) Rear 2.2 bar (32 psi) Secondary drive ratio 16:42 Chain 5/8 x 1/4”…

• Page 178: Tires

  Rear tires 120/70 R 17 M/C 58H TL 160/60 R 17 M/C 69H TL Continental Conti Attack SM Continental Conti Attack SM Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork Fork part number 14.18.8N.12 Fork WP Performance Systems 4860 ROTA SPLIT…

• Page 179: Shock Absorber

  TECHNICAL DATA Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring length with preload spacer(s) 463 mm (18.23 in) Spring rate Medium (standard) 5.3 N/mm (30.3 lb/in) Air chamber length mm (4.33 +0.79…

• Page 180: Chassis Tightening Torques

  TECHNICAL DATA Standard 20 clicks Sport 15 clicks Full load capacity 15 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring preload 20 mm (0.79 in) Spring rate Medium (standard) 80 N/mm (457 lb/in) Hard 85 N/mm (485 lb/in) Spring length…

• Page 181
  TECHNICAL DATA – Screw, side stand switch EJOT 2 Nm (1.5 lbf ft) – Screw, SLS valve EJOT 2 Nm (1.5 lbf ft) – Fitting, side stand switch 2 Nm (1.5 lbf ft) – Spoke nipple, front wheel M4.5 4 Nm (3 lbf ft) –…
• Page 182
  TECHNICAL DATA – Screw, air filter box top 2 Nm (1.5 lbf ft) Screw, ball joint of push rod on foot 10 Nm (7.4 lbf ft) Loctite ® 243™ brake cylinder – Screw, brake assembly 5 Nm (3.7 lbf ft) –…
• Page 183
  TECHNICAL DATA – Screw, chain sliding piece 15 Nm (11.1 lbf ft) Screw, connection lever on frame 30 Nm (22.1 lbf ft) Loctite ® 243™ Screw, foot brake lever 25 Nm (18.4 lbf ft) Loctite ® 243™ – Screw, fork stub 15 Nm (11.1 lbf ft) –…
• Page 184
  TECHNICAL DATA – Screw, engine bearer on frame 45 Nm (33.2 lbf ft) Screw, handlebar support 40 Nm (29.5 lbf ft) Loctite ® 243™ Screw, side stand 35 Nm (25.8 lbf ft) Loctite ® 243™ Loctite ® 243™ Screw, top shock absorber 45 Nm (33.2 lbf ft) –…

• Page 185: Substances

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

• Page 186
  SUBSTANCES – 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 Recommended supplier Motorex ® – Cross Power 4T Engine oil (SAE 10W/50) Standard/classification –…
• Page 187
  SUBSTANCES Hydraulic fluid (15) Standard/classification – 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. Recommended supplier Motorex ® – Hydraulic Fluid 75 Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –…

• Page 188: Auxiliary Substances

  AUXILIARY SUBSTANCES Chain cleaner Recommended supplier Motorex ® – Chain Clean Chain lube for road use Guideline Recommended supplier Motorex ® – Chainlube Road Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Long-life grease Recommended supplier Motorex ® – Bike Grease 2000 Motorcycle cleaner Recommended supplier…

• Page 189
  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 190: Standards

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

• Page 191: Index Of Special Terms

  INDEX OF SPECIAL TERMS Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces Malfunction indicator lamp Indicator lamp that supports vehicle diagnostics through flash codes On-board diagnosis Vehicle system that monitors emission- and safety-related values…

• Page 192: List Of Abbreviations

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

• Page 193: List Of Symbols

  LIST OF SYMBOLS 28.1 Red symbols Red symbols indicate an error condition that requires immediate intervention. The temperature warning lamp lights up red – The coolant temperature has reached a critical value. The oil pressure warning lamp lights up red – The oil pressure is too low. The battery warning lamp lights up red –…

• Page 194
  LIST OF SYMBOLS The idling speed indicator lamp lights up green – The transmission is shifted to idle. The high beam indicator lamp lights up blue – The high beam is switched on.

• Page 195: Index

  INDEX INDEX Brake linings front brake, checking ……93 ABS ……… 88 rear brake, checking .

• Page 196
  INDEX coolant temperature indicator ….. 36 Engine characteristic display ……..30 adjusting .
• Page 197
  INDEX rebound, adjusting ……63 Horn button ……..24 Fork part number .
• Page 198
  INDEX removing ……..146 Oil screens Safe operation ……..11 cleaning .
• Page 199
  INDEX rear right ……..18 Technical data Warranty .
• Page 200
  *3213394en* 3213394en 09/2015 KTM Sportmotorcycle GmbH Photo: Mitterbauer/KTM 5230 Mattighofen/Austria http://www.ktm.com…

1. Manuals
2. Brands
3. KTM Manuals
4. Motorcycle
5. Chassis 690 SMC
6. Owner’s manual

• Page 1
  OWNER’S MANUAL 2008 690 SMC USA ART. NO. 3211305en…
• Page 3
  KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, as well as printing and other errors.
• Page 4
  Reproduction, even in part, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.

• Page 5: Table Of Contents

  CONTENTS Combination instrument — control lamps ……32 CONTENTS MEANS OF REPRESENTATION ……….7 Combination instrument — Display ……..33 IMPORTANT NOTES …………… 8 Combination instrument — speed display ……34 Overview of warning labels……….10 Setting kilometers or miles ……….34 VIEW OF VEHICLE…………..

• Page 6
  Adjusting chain tension…………. 79 Important maintenance work to be carried out by an Checking rear sprocket / engine sprocket for wear ….81 authorized KTM workshop. (as additional order)….61 Checking chain wear …………82 MAINTENANCE WORK ON CHASSIS AND ENGINE ….63 Adjusting chain guide …
• Page 7
  CONTENTS Tire condition checking……….. 107 Adjusting play in gas Bowden cable  ……139 Checking spoke tension……….. 108 Checking engine oil level……….140 Checking tire air pressure ……….109 Changing engine oil and oil filter, cleaning oil screens  …………..140 Removing the seat …………110 Mounting the seat …………
• Page 8
  CONTENTS SUBSTANCES…………..173 AUXILIARY SUBSTANCES……….. 176 STANDARDS…………..178 INDEX …………….179…

• Page 9: Means Of Representation

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

• Page 10: Important Notes

  IMPORTANT NOTES 2 I MPORTANT NOTES Use definition KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race courses or offroad. Info The motorcycle is authorized for public road traffic in the homologous version only.

• Page 11
  Spare parts, accessories In the interests of your own safety, use only spare parts and accessories approved and/or recommended by KTM, and have these fitted in an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage.

• Page 12: Overview Of Warning Labels

  IMPORTANT NOTES Overview of warning labels 100330-10…

• Page 13
  IMPORTANT NOTES Type label, Canada Type label, USA Information, emission control Information, noise emission Information, suspension setting Information, chain tension Information, fuel evaporation system Information, putting into operation 100341-01 Type label, Canada…
• Page 14
  IMPORTANT NOTES 100340-01 Type label, USA 100339-01 Information, emission control…
• Page 15
  IMPORTANT NOTES 100342-01 Information, noise emission Information, suspension setting 100344-01…
• Page 16
  IMPORTANT NOTES Information, chain tension 100338-01 Information, fuel evaporation system 100336-01 Information, putting into operation 700210-01…
• Page 17
  IMPORTANT NOTES notes/warnings Be sure to pay attention to the notes and warnings given here. Info Various notes and warning stickers are attached to the vehicle. Do not remove any notes and warning stickers. If these are removed, you or other persons may not recognize potential danger and therefore be liable to injury. Grades of risks Danger Danger of leading to immediate, certain, serious, permanent injuries or death.
• Page 18
  Noise emission warranty KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.
• Page 19
  Consumer rights Limited warranty claims should be directed to an authorized KTM dealer. If you are not satisfied, please contact: KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA Telephone: (440) 985–3553…

• Page 20: View Of Vehicle

  VIEW OF VEHICLE 3 V IEW OF VEHICLE View of vehicle, front left side 100328-10…

• Page 21
  VIEW OF VEHICLE Hand brake lever Clutch lever Seat Filler cap Front brake caliper Shift lever Engine number Side stand Footrest Seat release strap…

• Page 22: View Of Vehicle, Rear Right Side

  VIEW OF VEHICLE View of vehicle, rear right side 100329-10…

• Page 23
  VIEW OF VEHICLE Ignition/steering lock Light switch, flasher switch, horn button Rear mirror Combination instrument Emergency OFF switch, electric starter button Throttle grip Rear brake caliper Shock absorber rebound damping Foot brake pedal Engine oil level viewer…

• Page 24: Location Of Serial Numbers

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

• Page 25: Key Number

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

• Page 26: Fork Part Number

  LOCATION OF SERIAL NUMBERS Fork part number The fork part number  is stamped on the inner side of the fork stub.  600480-10 Shock absorber part number Shock absorber part number  can be viewed from the right side.  100216-10…

• Page 27: Operating Elements

  OPERATING ELEMENTS 5 O PERATING ELEMENTS Clutch lever The clutch lever  is fitted on the left side of the handlebar.  The clutch is hydraulically operated and self-adjusting. 600481-10 Hand brake lever The hand break lever  is fitted on the right side of the handlebar. …

• Page 28: Light Switch

  OPERATING ELEMENTS Light switch The light switch  is fitted on the left side of the handlebar.  Possible states Low beam on – Light switch is turned downwards. In this position, the low beam and tail light are switched on. High beam on – Light switch is turned upwards. In this position, the high beam and the tail light are switched on.

• Page 29: Headlight Flasher Switch

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

• Page 30: Flasher Switch

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

• Page 31: Horn Button

  OPERATING ELEMENTS 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 position. • Horn button  100224-10 Emergency OFF switch 5.10 The emergency OFF switch …

• Page 32: Electric Starter Button

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

• Page 33: Combination Instrument

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

• Page 34: Combination Instrument — Tachometer

  OPERATING ELEMENTS Combination instrument — tachometer 5.15 The tachometer  displays the engine speed in revolutions per minute.  The red marking  shows the excess engine speed range.  100118-10 Combination instrument — control lamps 5.16 The indicator lamps provide additional information on the operating state of the motorcycle. Possible states Flashing indicator flashes green in flash rhythm – Flasher light is switched Idling speed indicator lamp lights up green – Transmission is in neutral.

• Page 35: Combination Instrument — Display

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

• Page 36: Combination Instrument — Speed Display

  OPERATING ELEMENTS Combination instrument — speed display 5.18 The speed  is displayed in kilometers per hour km/h or miles per hour Mph.  700114-01 Setting kilometers or miles 5.19 Info If you change the unit, the ODO value is retained and converted accordingly. Making the setting according to the country.

• Page 37: Combination Instrument — Time

  OPERATING ELEMENTS – Switch on the ignition by turning the ignition key in the position  . – Press the MODE button several times until the ODO display mode is active. – Keep the MODE button pressed until the display mode changes from Km/h to Mph or from Mph to Km/h.

• Page 38: Combination Instrument — Odo Display

  OPERATING ELEMENTS – Switch on the ignition by turning the ignition key in the position  . – Press the MODE button several times until the ODO display mode is active. – Keep the MODE button and the SET button pressed simultaneously. The time begins to flash. – Press the MODE button to adjust the hour.

• Page 39: Combination Instrument — Setting/Resetting Trip 2 Display

  OPERATING ELEMENTS – Switch on the ignition by turning the ignition key in the position  . – Press the MODE button several times until the TRIP 1 display mode is active. – Keep the SET button pressed. The TRIP 1 display is at 0.0. 700121-01 Combination instrument — setting/resetting TRIP 2 display 5.24 Info The tripmaster TRIP 2 operates constantly and counts up to 999.9.

• Page 40: Combination Instrument — Trip F Display

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

• Page 41: Opening Filler Cap

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

• Page 42: Handrails

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

• Page 43: Passenger Footrests

  OPERATING ELEMENTS Passenger footrests 5.31 The passenger footrests can be folded up and down. Possible states Passenger footrests folded up – For operation without a passenger. • Passenger footrests folded down – For operation with a passenger. • 600640-01 Shift lever 5.32 The shift lever  is mounted on the left side of the engine.

• Page 44: Foot Brake Pedal

  OPERATING ELEMENTS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 600484-11 Foot brake pedal 5.33 The footbrake pedal  is located in front of the right footrest.  The footbrake pedal operates the rear brake.

• Page 45: Side Stand

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

• Page 46: General Tips On Putting Into Operation

  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 characteristics 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 47: Running In The Engine

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

• Page 48: Loading The Vehicle

  GENERAL TIPS ON PUTTING INTO OPERATION – Avoid fully opening the throttle! Loading the vehicle Warning Danger of accidents Unstable riding behavior. – Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage.

• Page 49
  GENERAL TIPS ON PUTTING INTO OPERATION Warning Danger of accidents Unstable handling characteristics due to slipped baggage. – Check the way your baggage is fixed regularly. Warning Danger of burns A hot exhaust system can burn baggage. – Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system. –…

• Page 50: Riding Instructions

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

• Page 51: Starting

  RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space. Caution Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety equipment may be damaged.

• Page 52
  RIDING INSTRUCTIONS – Turn the emergency OFF switch to the position  . – Switch on the ignition by turning the ignition key in the position  . After switching on the ignition, you can hear the fuel pump working for about 2 seconds.

• Page 53: Starting Up

  RIDING INSTRUCTIONS Starting up – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully. Shifting, riding Warning Danger of accidents An abrupt load alterations can cause the vehicle to get out of control. –…

• Page 54
  RIDING INSTRUCTIONS Warning Danger of accidents Reduced road grip with cold tires. – On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured. Warning Danger of accidents Reduced road grip with new tires. –…
• Page 55
  If you continue with the coolant temperature warning lamp alight, you may have engine failure. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. – When conditions allow (incline, road situation, etc.), you can shift into a higher gear.

• Page 56: Braking

  Clean or dry dirty or wet brakes by riding and braking gently. Warning Danger of accidents Reduced braking caused by spongy pressure point of front or rear brake. – Have the brake system checked in an authorized KTM workshop, and do not ride any further.

• Page 57: Stopping, Parking

  RIDING INSTRUCTIONS Warning Danger of accidents Brake system failure. – If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take your foot off the foot brake pedal if you do not want to brake. Warning Danger of accidents Longer stopping distance due to higher overall weight.

• Page 58
  RIDING INSTRUCTIONS Warning Danger of burns Some vehicle components get very hot when the machine is driven. – Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these components to cool down before starting work on them. Note Danger of damage Danger of damage by the vehicle running away or falling over.

• Page 59: Refueling

  RIDING INSTRUCTIONS – Lock the steering by moving the handlebar to the left, pressing down the ignition key in the position  and turning it to the position  . To make locking the steering easier, move the handlebar a little to the left and right. Remove the ignition key. Refueling Danger Fire hazard Fuel can easily catch fire.

• Page 60
  RIDING INSTRUCTIONS – switch off engine. – Open the filler cap. ( S. 39) – Fill the fuel tank with fuel up to measurement   Guideline Measurement of  20 mm (0.79 in)  Fuel tank content 12 l (3.2 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( S.

• Page 61: Greasing And Service Table

  GREASING AND SERVICE TABLE 8 G REASING AND SERVICE TABLE Important maintenance work to be carried out by an authorized KTM workshop. K10N K50A K100A Engine Change engine oil and oil filter, clean oil screens.  S. 140) • • •…

• Page 62
  GREASING AND SERVICE TABLE K10N K50A K100A Attachments Check the functioning of the electrical equipment. • • • • • Check screws and nuts for tightness. • • • • • Brakes Check the front brake linings. ( S. 88) •…

• Page 63: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop. (As Additional Order)

  K50A: every 5,000 km (3,107 mi) / after every race K100A: every 10,000 km (6,214 mi) J1A: annually J2A: every 2 years Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) K100A Carry out a complete fork service.  •…

• Page 64
  GREASING AND SERVICE TABLE J2A: every 2 years…

• Page 65: Maintenance Work On Chassis And Engine

  MAINTENANCE WORK ON CHASSIS AND ENGINE 9 M AINTENANCE WORK ON CHASSIS AND ENGINE Jacking up front of motorcycle Note Danger of damage Danger of damage by the vehicle running away or falling over. – Always place the vehicle on a firm and even surface. –…

• Page 66: Jacking Up Rear Of Motorcycle

  MAINTENANCE WORK ON CHASSIS AND ENGINE Jacking up rear of motorcycle Note Danger of damage Danger of damage by the vehicle running away or falling over. – Always place the vehicle on a firm and even surface. – Insert the work stand adapter in the work stand and screw it into the link forks. Work stand adapter (61029055110) Work stand rear (61029055100) –…

• Page 67: Fork/Shock Absorber

  MAINTENANCE WORK ON CHASSIS AND ENGINE 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 68: Adjusting Rebound Damping Of Fork

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn back counterclockwise the number of clicks corresponding to the fork type. Guideline Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

• Page 69: Compression Damping Of Shock Absorber

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn back counterclockwise the number of clicks corresponding to the fork type. Guideline Rebound damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks full payload 5 clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

• Page 70: Adjusting High-Speed Compression Damping Of The Shock Absorber

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn the adjusting screw  clockwise with a screwdriver until it stops.  Info Do not loosen nut   – Turn back counterclockwise the number of clicks corresponding to the shock absorber type. Guideline Compression damping, low-speed Comfort 20 clicks…

• Page 71
  MAINTENANCE WORK ON CHASSIS AND ENGINE Info The high-speed setting can be seen during the fast compression of the shock absorber. – Turn the adjusting screw  clockwise with an open-ended spanner until it stops.  Info Do not loosen nut  …

• Page 72: Adjusting Rebound Damping Of The Shock Absorber

  MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting rebound damping of the shock absorber 9.11 Danger Danger of accidents The shock absorber is under high pressure. – The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any mainte- nance on it yourself.

• Page 73: Cleaning Dust Boots Of Fork Legs

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove bleeder screws  briefly.  Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. Info Carry out this action on both fork legs. 100248-10 Cleaning dust boots of fork legs 9.13 –…

• Page 74: Removing The Fork Protector

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

• Page 75: Installing The Fork Protector

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

• Page 76: Adjusting Play Of Steering Head Bearing

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: –…

• Page 77: Handlebar Position

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount and tighten screw   Guideline Screw, steering stem 20 Nm Loctite ® 243™ (14.8 lbf ft) – Check play of steering head bearing.  S. 73) – Remove the motorcycle from the work stand. Handlebar position 9.18 On the upper triple clamp, there are 2 holes at a distance …

• Page 78: Adjusting Handlebar Position

  MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting handlebar position  9.19 – Remove the four screws  . Remove the handlebar clamp. Remove the handlebar and  0 0 1 lay it to one side. 0 0 2 Info Protect the motorcycle and its attachments from damage by covering them. Do not bend the cables and lines.

• Page 79: Adjusting The Handlebar Angle

  MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the handlebar angle  9.20 – Loosen screw   – Move the handlebar to the desired position and slightly tichten the screws. – Move the handlebar carefully in both directions as far as it will go. »…

• Page 80: Checking The Chain Tension

  MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of accidents Reduced braking due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Environmental hazard Problem materials cause environmental damage.

• Page 81: Adjusting Chain Tension

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Lean the motorcycle on the side stand. – Shift gear to neutral. – Push the chain upward at a distance  from the chain sliding guard and determine the  chain tension   Info The upper chain section …

• Page 82
  MAINTENANCE WORK ON CHASSIS AND ENGINE – Lean the motorcycle on the side stand. – Shift gear to neutral. – Loosen nut   – Loosen nuts   – Adjust the chain tension by turning the adjusting screws  left and right. …

• Page 83: Checking Rear Sprocket / Engine Sprocket For Wear

  The engine sprocket, rear sprocket and chain should always be replaced together. For safety reasons, the chain has no chain joint. Always have the chain replaced in an authorized KTM workshop, where the necessary chain rivet tool is available. 100132-10 –…

• Page 84: Checking Chain Wear

  A new chain will wear faster on an old, worn rear sprocket or engine 1 2 3 16 17 18 sprocket. 400409-10 For safety reasons, the chain has no chain joint. Always have the chain changed in an authorized KTM workshop, where they have the necessary special tools.

• Page 85: Adjusting Chain Guide

  Mount and tighten screws  and    Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 600635-10 Checking brake discs 9.28 Warning Danger of accidents Reduced braking due to worn brake discs. – Worn brake discs should be replaced immediately in an authorized KTM workshop.

• Page 86: Adjusting Basic Position Of Handbrake Lever

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement   Info Wear reduces the thickness of the brake disc around the area used by the brake linings.

• Page 87: Checking Front Brake Fluid Level

  Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. – The brake fluid level must not fall below the center of the level viewer …

• Page 88
  If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –…

• Page 89: Brake Linings

  Clean up overflowed or spilt brake fluid immediately with water. Brake linings 9.32 The brake linings fitted by KTM were tested over long periods and ensure optimal braking properties. The type names of brake pads are entered in the homologation documents. Info Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles.

• Page 90: Checking The Front Brake Linings

  If the minimum thickness is less than specified: – Change the front brake linings.  S. 88) 600625-10 Changing the front brake linings  9.34 Warning Danger of accidents Improper brake maintenance and repair. – Always have your brake system maintained and repaired in an authorized KTM workshop.

• Page 91
  Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin- ings.

• Page 92: Removing Front Brake Linings

  Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water. 100254-12 Removing front brake linings  9.35 Warning Danger of accidents Improper brake maintenance and repair. – Always have your brake system maintained and repaired in an authorized KTM workshop.

• Page 93: Mounting Front Brake Linings

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Press the spring hanger of the spring  forwards and withdraw the bolt    – Take off the springs  . Remove brake linings    400421-11 – Remove screw  and spacing sleeve  . Remove the brake caliper. …

• Page 94
  Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin- ings.

• Page 95: Checking Free Play Of Foot Brake Lever

  MAINTENANCE WORK ON CHASSIS AND ENGINE Checking free play of foot brake lever 9.37 Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can fail due to overheating.

• Page 96: Checking Rear Brake Fluid Level

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

• Page 97: Topping Up Brake Fluid Of Rear Brake

  MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. – Stand the vehicle upright. –…

• Page 98
  MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –…

• Page 99: Checking The Rear Brake Linings

  If the minimum thickness is less than specified: – Change the rear brake linings.  S. 97) 100260-10 Changing rear brake linings  9.42 Warning Danger of accidents Improper brake maintenance and repair. – Always have your brake system maintained and repaired in an authorized KTM workshop.

• Page 100
  Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin- ings.
• Page 101
  MAINTENANCE WORK ON CHASSIS AND ENGINE – Stand the vehicle upright. – Remove screw cover  with membrane    – Press the brake caliper by hand on to the brake disc in order to press back the brake piston. Ensure that brake fluid does not overflow from the brake fluid reservoir and suc- tion it off if necessary.

• Page 102: Removing Front Wheel

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Insert the brake pads, insert the bolt and mount the split pin. – Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot. –…

• Page 103
  MAINTENANCE WORK ON CHASSIS AND ENGINE – Loosed screw  and screw    – Screw out screw  about 6 turns, press your hand on the screw to push the wheel spin-  dle out of the fork stub. Remove screw  …

• Page 104: Installing The Front Wheel

  MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the front wheel  9.44 Warning Danger of accidents Reduced braking due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

• Page 105: Removing Rear Wheel

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc. – Take the front from the work stand. ( S. 63) – Pull the front wheel brake and push down hard on the fork several times to align the fork legs.

• Page 106: Installing The Rear Wheel

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Push the rear wheel forwards as far as possible and take the chain off the rear sprocket. Warning Danger of accidents Reduced braking due to damaged brake discs. – Always lay the wheel down in such a way that the brake disc is not damaged. –…

• Page 107
  MAINTENANCE WORK ON CHASSIS AND ENGINE – Check parts for damage and wear. Replace damaged or worn parts. – Remove the bushing  . Clean and grease the roll surfaces of the bushing and the shaft  seal ring   Long-life grease ( S.

• Page 108: Checking The Rear Hub Rubber Dampers

  MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the rear hub rubber dampers  9.47 Info The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged. –…

• Page 109: Tire Condition Checking

  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 characteristics 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 110: Checking Spoke Tension

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

• Page 111: Checking Tire Air Pressure

  MAINTENANCE WORK ON CHASSIS AND ENGINE – To check spoke tension, tap each spoke with a screwdriver. Guideline You should hear a high note. Spoke nipple, front wheel M4,5 4 Nm (3 lbf ft) Spoke nipple, rear wheel 4 Nm (3 lbf ft) Info If you hear different tone frequencies from different spokes, this is an indication 600632-01 of different spoke tensions.

• Page 112: Removing The Seat

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount dust cap. Removing the seat 9.51 – Pull on strap  and raise the rear of the seat at the same time.  – Pull back the seat and lift it off. 100230-10 Mounting the seat 9.52 –…

• Page 113: Removing The Battery

  MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the battery  9.53 Warning Risk of injury Battery acid and battery gases cause serious cauterization. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –…

• Page 114: Installing The Battery

  MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the battery  9.54 – Slide the battery into the battery rack. Info The battery terminals must be at the rear. – Attach the positive cable and mount positive terminal cover   – Position retaining bracket  …

• Page 115
  MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Environmental hazard Components and battery acid are a danger to the environment. – Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator. Warning Environmental hazard Problem materials cause environmental damage. –…

• Page 116: Changing The Main Fuse

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the bat- tery, and to test the generator. With this device, you cannot overcharge the battery. Info Never remove the lid …

• Page 117
  A reserve fuse  is located in the starter relay.  – Fit a new main fuse. Fuse (58011109130) ( S. 165) 600605-10 Info If the new fuse burns out, contact an authorized KTM workshop. – Check the functioning of the electrical equipment.

• Page 118: Changing Fuses Of Individual Power Consumers

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Attach the protection covers. – Mount the seat. ( S. 110) – Set the clock. ( S. 35) Changing fuses of individual power consumers 9.57 Info The fuse box containing the fuses of individual power consumers is located under the seat. –…

• Page 119
  MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove defective fuse. Guideline Fuse 1 — 10A — ignition, combination instrument, alarm system (optional) Fuse 2 — 10A — clock, ignition (EFI control unit) Fuse 3 — 10A — throttle valve control unit Fuse 4 — 10A — fuel pump Fuse 5 — 10A — radiator fan Fuse 6 — 10A — horn, brake light, flasher light, alarm system (optional) Fuse 7 — 15A — high beam, low beam, parking light, tail light, license plate lamp…

• Page 120: Adjusting The Engine Characteristic

  Fuse (75011088015) ( S. 165) Info If the new fuse burns out, contact an authorized KTM workshop. Replace the spare fuse in the fuse box so that it will be available if needed. – Check the functioning of the power consumer.

• Page 121
  MAINTENANCE WORK ON CHASSIS AND ENGINE – Pull the Map‑Select switch and holder  upward off of the retaining bracket.  – Pull the Map‑Select switch out of the holder. 600641-10 – Turn the adjusting wheel until the desired digit is next to marking  …

• Page 122: Removing Headlight Mask With Headlight

  MAINTENANCE WORK ON CHASSIS AND ENGINE Removing headlight mask with headlight 9.59 – Switch off all power-consuming components and switch off the engine. – Protect the fender against damage by covering it with a cloth. – Remove the screws  on the left and right. …

• Page 123: Refitting The Headlight Mask With The Headlight

  MAINTENANCE WORK ON CHASSIS AND ENGINE Refitting the headlight mask with the headlight 9.60 – Connect the connectors of headlight  and flasher lights    – Check lighting function. 100294-11 – Remove the cloth from the fender, attach the headlight mask to points  on the fender …

• Page 124: Changing The Headlight Bulb

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Position brake-hose guide  . Mount and tighten screws    Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 100296-10 Changing the headlight bulb 9.61 Note Damage to reflector Keep the glass of the bulb free of grease. –…

• Page 125: Changing The Parking Light Bulb

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Detach spring bar   – Remove headlight bulb   – Insert a new headlight bulb into the headlight housing. Headlight (H4/P43t) ( S. 165) – Fit the headlight bulb in the headlight using the spring bar. –…

• Page 126: Changing The Rear Lamp

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Pull bulb socket  out of the reflector.  – Pull parking light bulb  out of the bulb socket.  – Check parts for damage and wear. Replace damaged or worn parts. – Insert a new parking light bulb into the bulb socket. Parking light (W2,1×9,5d) ( S.

• Page 127: Changing The Flasher Bulb

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Check the function of the rear lamp and the brake light. – Check that the seal  is correctly seated. Position the lens.  – Insert the screws and turn them first counterclockwise until you feel them click into the thread.

• Page 128: Checking Headlamp Setting

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Check the flasher function. Checking headlamp setting 9.65 – On a light-colored wall with a horizontal area in front of it, make a mark as high as the 0 0 A center of the low beam headlight. –…

• Page 129: Removing The Air Filter

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Use a screwdriver (see illustration) to adjust the headlight range. Guideline The boundary between light and dark must be exactly on the lower mark for a motor- cycle with a rider (mark is applied under: Checking headlight adjustment). Info Turn clockwise to increase the light range, turn counterclockwise to reduce the light range.

• Page 130: Installing The Air Filter

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

• Page 131: Cooling System

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount and tighten screws   Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Mount the seat. ( S. 110) 100285-11 Cooling system 9.69 The water pump  in the engine forces the coolant to flow. …

• Page 132: Checking The Antifreeze And Coolant Level

  MAINTENANCE WORK ON CHASSIS AND ENGINE The coolant is cooled by the air stream and a radiator fan  , which is controlled by a ther-  moswitch. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect.

• Page 133
  MAINTENANCE WORK ON CHASSIS AND ENGINE Condition Engine is cold. – Stand the motorcycle on its side stand on a horizontal surface. – Remove the cap of the compensating tank   – Check antifreeze of coolant. −25… −45 °C (−13… −49 °F) »…

• Page 134: Checking The Coolant Level

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Screw off the radiator cap   – Check antifreeze of coolant. −25… −45 °C (−13… −49 °F) » If the antifreeze of the cooling liquid does not meet specifications: – Correct antifreeze of coolant. – Check the coolant level in the radiator.

• Page 135
  MAINTENANCE WORK ON CHASSIS AND ENGINE Warning Danger of poisoning Coolants are poisonous and a health hazard. – Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and con- tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.

• Page 136: Draining Coolant

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Screw off the radiator cap  and check the coolant level in the radiator.  The radiator must be completely full. » If the level of the cooling liquid does not meet specifications: – Correct the coolant level and find out the cause of the loss.

• Page 137: Filling The Cooling System

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Stand the vehicle upright. – Place a suitable container under the engine. – Remove screw  . Remove the radiator cap.  – Completely drain the coolant. – Fit screw  with a new seal and tighten it. …

• Page 138
  MAINTENANCE WORK ON CHASSIS AND ENGINE – Refill the coolant. Alternative 1 Coolant ( S. 173) Alternative 2 Coolant (mixed ready to use) ( S. 173) – Fill the radiator completely with coolant. Mount radiator cap   600619-10 – Remove the cap from compensating tank  and add coolant to the level shown in the …

• Page 139: Adjusting Basic Position Of Clutch Lever

  MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting basic position of clutch lever 9.74 Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar. The range of adjustment is limited.

• Page 140: Checking Play In Gas Bowden Cable

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screws   – Remove the cover  with membrane    – Check the fluid level. Fluid level under top level of container. 4 mm (0.16 in) » If the fluid level does not meet specifications: –…

• Page 141: Adjusting Play In Gas Bowden Cable

  MAINTENANCE WORK ON CHASSIS AND ENGINE Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space. –…

• Page 142: Checking Engine Oil Level

  MAINTENANCE WORK ON CHASSIS AND ENGINE Checking engine oil level 9.78 Info The engine oil level must be checked when the engine is at operating temperature. – Stand the motorcycle upright on a horizontal surface. Condition The engine is at operating temperature. –…

• Page 143: Draining Engine Oil

  MAINTENANCE WORK ON CHASSIS AND ENGINE Draining engine oil  9.80 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. – Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately. Warning Environmental hazard Problem materials cause environmental damage.

• Page 144: Removing The Oil Filter

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Thoroughly clean the oil drain plug with a magnet. – Check parts for damage and wear. Replace damaged or worn parts. – Refit the oil drain plug with the magnet and seal ring and tighten it. Guideline Oil drain plug with magnet M12x1,5…

• Page 145
  MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screws  . Remove oil filter cover  with O-ring.   – Pull the oil filter insert  out of the oil filter casing.  Circlip pliers reverse (51012011000) 100202-10 – Remove screws  . Remove oil filter cover  with O-ring.

• Page 146: Mounting Oil Filter

  MAINTENANCE WORK ON CHASSIS AND ENGINE Mounting oil filter  9.82 – Check parts for damage and wear. Replace damaged or worn parts. – Insert oil filter  and    – Oil the O-rings of the oil filter cover. Refit the oil filter cover  and …

• Page 147
  MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove the plug  with the oil screen  and O-rings.   100205-10 – Remove the plug  with the oil screen  and O-rings.   – Drain the remaining engine oil. – Thoroughly clean parts and sealing area. –…

• Page 148: Filling Up With Engine Oil

  MAINTENANCE WORK ON CHASSIS AND ENGINE – Position oil screen  with O-rings.  – Refit plug  with O-ring and tighten it.  Guideline Plug, oil screen M20x1,5 15 Nm (11.1 lbf ft) 100208-10 Filling up with engine oil  9.84 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. –…

• Page 149: Topping Up Engine Oil

  MAINTENANCE WORK ON CHASSIS AND ENGINE Topping up engine oil 9.85 Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. – Remove filler plug with O-ring  from the clutch cover and add engine oil. …

• Page 150: Troubleshooting

  Socket connector of cable harness oxidized Clean socket connector and treat it with contact spray. – Defect in fuel injection system Read the error memory with the KTM diagnostics tool and correct the fault. – Engine has too little power. Air filter very dirty…

• Page 151
  Engine has too little power. Fuel filter very dirty Have the fuel filter changed. – Defect in fuel injection system Read the error memory with the KTM diagnostics tool and correct the fault. – Engine overheats. Too little coolant in cooling system Check the cooling system for leakage.
• Page 152
  TROUBLESHOOTING Faults Possible cause Action – Headlight and parking light not functioning Fuse 7 blown Change the fuses of individual power consumers. ( S. 116) – Flasher light, brake light and horn not Fuse 6 blown Change the fuses of individual power functioning consumers.

• Page 153: Flashing Code

  FLASHING CODE FLASHING CODE Fault Description Possible cause Action – FI warning lamp (MIL) flashes Malfunction in ignition pulse Check the ignition pulse briefly 2x generator circuit generator.  – FI warning lamp (MIL) flashes Input signal from throttle valve Check the throttle valve sen- briefly 6x sensor too low/high sor. …

• Page 154
  FLASHING CODE Fault Description Possible cause Action – FI warning lamp (MIL) flashes 2x Malfunction in voltage supply Check the throttle valve con- long, 7x short circuit of throttle valve control trol unit voltage supply.  unit – FI warning lamp (MIL) flashes 3x Malfunction in injection valve Check the injection long, 3x short…
• Page 155
  FLASHING CODE Fault Description Possible cause Action – FI warning lamp (MIL) flashes 9x Throttle valve position not plau- Check the throttle valve long sible position.  – FI warning lamp (MIL) flashes 9x Malfunction in CAN bus com- Check CAN bus communica- long, 1x short munication tion. …

• Page 156: Cleaning

  CLEANING CLEANING Cleaning motorcycle 12.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Problem materials cause environmental damage.

• Page 157
  CLEANING Warning Danger of accidents Reduced braking due to wet or dirty brakes. – Clean or dry dirty or wet brakes by riding and braking gently. – After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes. Info The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.

• Page 158: Conservation For Winter Operation

  CONSERVATION FOR WINTER OPERATION CONSERVATION FOR WINTER OPERATION Conservation for winter operation 13.1 Info If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt. If you have ridden the vehicle on salted roads, clean it with cold water. Warm water would reinforce the effect of the salt. –…

• Page 159: Storage

  Storage temperature of battery without direct sunshine. 0… 35 °C (32… 95 °F) – The storage place should be dry and not subject to large temperature differences. Info KTM recommends jacking up the motorcycle. – Jack up the rear of the motorcycle. ( S. 64) –…

• Page 160: Putting Into Operation After Storage

  STORAGE – Cover the motorcycle with a porous sheet or blanket. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust.

• Page 161: Technical Data — Engine

  TECHNICAL DATA — ENGINE TECHNICAL DATA — ENGINE Design 1-cyliner 4-stroke engine, water-cooled Displacement 654 cm³ (39.91 cu in) Stroke 80 mm (3.15 in) Bore 102 mm (4.02 in) Compression ratio 11,8:1 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) Valve play, cold…

• Page 162: Capacity — Engine Oil

  TECHNICAL DATA — ENGINE 6th gear 23:20 Mixture preparation Electronic fuel injection Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Generator 12 V, 224 W Spark plug NGK LKAR 8AI — 9 spark plug electrode gap 0.9 mm (0.035 in) Cooling Water cooling, permanent circulation of coolant by water pump Starting aid Electric starter, automatic decompressor Capacity — engine oil…

• Page 163: Technical Data — Engine Tightening Torques

  TECHNICAL DATA — ENGINE TIGHTENING TORQUES TECHNICAL DATA — ENGINE TIGHTENING TORQUES ® Plug, oil bore self-tapping 9 Nm (6.6 lbf ft) Loctite 243™ ® Screw, membrane fixation 2.5 Nm (1.84 lbf ft) Loctite 243™ ® Oil jet, conrod lubrication 2 Nm (1.5 lbf ft) Loctite 243™ – Hose clamp, intake flange 1.5 Nm (1.11 lbf ft) –…

• Page 164
  TECHNICAL DATA — ENGINE TIGHTENING TORQUES – Screw, engine housing 10 Nm (7.4 lbf ft) ® Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite 243™ ® Screw, shift lever 10 Nm (7.4 lbf ft) Loctite ® Screw, timing chain tensioning rail 10 Nm (7.4 lbf ft) Loctite 243™ ® Screw, starter motor 10 Nm (7.4 lbf ft) Loctite 243™…
• Page 165
  TECHNICAL DATA — ENGINE TIGHTENING TORQUES Screw, cylinder head Tightening sequence: lubricated with engine oil Tighten diagonally, beginning with the rear screw on the 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) Step 4 60 Nm (44.3 lbf ft) –…

• Page 166: Technical Data — Chassis

  TECHNICAL DATA — CHASSIS TECHNICAL DATA — CHASSIS Frame Lattice frame made of chrome molybdenum steel tubing, powder- coated Fork WP Suspension Up Side Down 4860 ROMA Shock absorber WP Suspension 4618 with Pro‑Lever deflector Suspension travel front 275 mm (10.83 in) Rear 265 mm (10.43 in) Brake system front Disc brake with radially screwed four-piston brake caliper, floating…

• Page 167: Lighting Equipment

  TECHNICAL DATA — CHASSIS Steering head angle 63° Wheelbase 1,480±15 mm (58.27±0.59 in) Seat height unloaded 900 mm (35.43 in) Ground clearance unloaded 290 mm (11.42 in) Weight without fuel 139.5 kg (307.5 lb.) Maximum permissible front axle load 150 kg (331 lb.) Maximum permissible rear axle load 200 kg (441 lb.) Maximum permissible overall weight 350 kg (772 lb.) Battery…

• Page 168: Capacity — Fuel

  Front tire Rear tire 120/70 ZR 17 M/C 58W TL 160/60 ZR 17 M/C 69W TL Pirelli Dragon Supercorsa Pro Pirelli Dragon Supercorsa Pro For further information, see the Service section under: http://www.ktm.com Capacity — fuel 17.2 Fuel tank content 12 l (3.2 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( S. 175) Fuel reserve 2.5 l (2.6 qt.)

• Page 169: Technical Data / Fork

  TECHNICAL DATA / FORK TECHNICAL DATA / FORK Fork part number 14.18.7D.12 Fork WP Suspension Up Side Down 4860 ROMA Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload 10 clicks Rebound damping Comfort 15 clicks Standard 10 clicks Sport 5 clicks full payload 5 clicks Spring length with preload spacer(s) 480 mm (18.9 in)

• Page 170: Technical Data — Shock Absorber

  TECHNICAL DATA — SHOCK ABSORBER TECHNICAL DATA — SHOCK ABSORBER Shock absorber part number 15.18.7D.12 Shock absorber WP Suspension 4618 with Pro‑Lever deflector Compression damping, high-speed Comfort 1.5 turns Standard 1 turn Sport 0.5 turn full payload 0.5 turn Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 10 clicks full payload…

• Page 171
  TECHNICAL DATA — SHOCK ABSORBER Static sag 20 mm (0.79 in) Riding sag 70… 80 mm (2.76… 3.15 in) Fitted length 400 mm (15.75 in)

• Page 172: Technical Data — Chassis Tightening Torques

  TECHNICAL DATA — CHASSIS TIGHTENING TORQUES TECHNICAL DATA — CHASSIS TIGHTENING TORQUES – Spoke nipple, front wheel M4,5 4 Nm (3 lbf ft) – Spoke nipple, rear wheel 4 Nm (3 lbf ft) – Remaining screws, chassis 4 Nm (3 lbf ft) – Screw, exhaust heat shield 8 Nm (5.9 lbf ft) –…

• Page 173
  TECHNICAL DATA — CHASSIS TIGHTENING TORQUES ® Screw, magnetic holder on side stand 10 Nm (7.4 lbf ft) Loctite 243™ – Screw, voltage regulator/rectifier 8 Nm (5.9 lbf ft) – Screw, SLS valve 4 Nm (3 lbf ft) ® Screw, ignition lock 10 Nm (7.4 lbf ft) Loctite 243™ ® Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite 243™…
• Page 174
  TECHNICAL DATA — CHASSIS TIGHTENING TORQUES – Screw, side stand bracket 25 Nm (18.4 lbf ft) – Screw, connection lever on frame 30 Nm (22.1 lbf ft) – Remaining nuts, chassis 50 Nm (36.9 lbf ft) – Remaining screws, chassis 45 Nm (33.2 lbf ft) ® Screw, front brake caliper M10x1.25 45 Nm (33.2 lbf ft) Loctite 243™…

• Page 175: Substances

  Brake fluid DOT 4 / DOT 5.1 according to – Specification – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Suppler Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®…

• Page 176
  SAE ( S. 178) (SAE 10W/60) Specification – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding ® properties. KTM recommends Motorex products. Synthetic engine oil Suppler ® Motorex –…
• Page 177
  SUBSTANCES Specification – Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Suppler ® Motorex – Hydraulic Fluid 75 Super unleaded (ROZ 95 / RON 95 / PON 91) according to –…

• Page 178: Auxiliary Substances

  AUXILIARY SUBSTANCES AUXILIARY SUBSTANCES Chain cleaner Specification – ® KTM recommends Motorex products. Suppler ® Motorex – Chain Clean 611 Cleaning and polishing materials for metal, rubber and plastic Specification – ® KTM recommends Motorex products. Suppler ® Motorex – Protect & Shine 645 Contact spray Specification –…

• Page 179
  AUXILIARY SUBSTANCES Long-life grease Specification – ® KTM recommends Motorex products. Suppler ® Motorex – Fett 2000 Motorcycle cleaner Specification – ® KTM recommends Motorex products. Suppler ® Motorex – Moto Clean 900 Onroad chain spray Specification – ® KTM recommends Motorex products. Suppler ®…

• Page 180: Standards

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

• Page 181: Index

  INDEX of rear brake, checking ……97 INDEX Removing front brake linings ….. 90 Accessories .

• Page 182
  INDEX Function buttons ……31 Engine characteristic Indicator lights ……. 32 adjusting .
• Page 183
  INDEX Bleeding fork legs ……70 removing ……..120 Fork part number .
• Page 184
  INDEX Oil screen Rear wheel cleaning ……..140 installing .
• Page 185
  INDEX Steering lock ……..30 Stopping ……..55 Storage .
• Page 186
  *3211305en* 3211305en 03/2008 Photo Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com…

Use definition

KTM sport motorcycles are designed and constructed to meet the normal demands of regular road and light offroad operation (dirt roads), but not for use on race courses.

Info

The motorcycle is authorized for public road traffic in the homologous version only.

Maintenance

A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in the owner’s manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of components.

Using the motorcycle in extreme conditions such as very muddy or wet roads can lead to above-average wear of components such as the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the greasing and service table is reached.

Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle.

Warranty

The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed in the customer’s service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.

Fuel, oils, etc.

Combination5.15 instrument — tachometer

The tachometer displays the engine speed in revolutions per minute.

The red marking shows the excess engine speed range.

100118-10

–Switch on the ignition by turning the ignition key in the position .

–Press the MODE button several times until the ODO display mode is active.

–Keep the MODE button pressed until the display mode changes from Km/h to Mph or from Mph to Km/h.

Specification

700120-01

Combination5.20 instrument — time

The time is shown in area of the display.

Info

The time must be adjusted after the battery is disconnected or the fuse is changed.

700115-01

Setting5.21 the clock

Condition

The motorcycle is standing.

–Switch on the ignition by turning the ignition key in the position .

–Press the MODE button several times until the ODO display mode is active.

–Keep the MODE button and the SET button pressed simultaneously.

The time begins to flash.

–Press the MODE button to adjust the hour.

–Press the SET button to adjust the minute.

–Keep the MODE button and the SET button pressed simultaneously.

Combination5.22 instrument — ODO display

In ODO mode, the total distance covered is shown in kilometers or miles.

Info

This value remains intact even if the battery is disconnected and/or the fuse blows.

700120-01

Combination5.23 instrument — setting/resetting TRIP 1 display

Info

The tripmaster TRIP 1 operates constantly and counts up to 999.9.

You can use the tripmaster to measure trips or the distance between refuelling stops. After reaching 999.9, the tripmaster begins again at 0.0.