KTM 690 SMC R (2014) manual

OWNER'S MANUAL 20 14 690 SMC R EU 690 SMC R AUS/UK Art. no. 3213104en[...]

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DEAR KTM CUSTOME R 1 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle . You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment in riding this vehicle. Enter the serial numbers of your vehicle below. C[...]

DEAR KTM CUSTOME R 2 ISO 9001(12 100 6061) According to the international quality managem ent standard ISO 9001, KTM uses quality assurance processe s that lead to the maximum possible quality of the products. Issued by: TÜV Management Service KTM-Sportmotorcy cle AG 5230 Mattighofen, Austria[...]

TABLE OF CONTENTS 3 TABLE OF CONTENTS 1 MEANS OF REPRESENTATION ............................ ............ 7 1.1 Symbols used ............................................. ......... 7 1.2 Formats used....................................................... 7 2 SAFETY ADVICE ..................... ............................ ............. 8 2.1 Use de[...]

TABLE OF CONTENTS 4 6.13 Seat release ................................................ ...... 38 6.14 Handra ils ................................................. ......... 38 6.15 Passen ger footrests ...... ............................ .......... 39 6.16 Shift lever .............................. ........................... 39 6.17 Foot brake lev[...]

TABLE OF CONTENTS 5 11.19 Adjusting basic position of clutch lever ................ 86 11.20 Checking/rectifyin g the fluid level of the hydraulic clutch ................... ............................ .. 87 12 BRAKE SYSTEM ............ ............................ ................... 88 12.1 ABS/ant ilock brake system .................. .........[...]

TABLE OF CONTENTS 6 17.3 Draining the engine oil x ............ .................... 143 17.4 Removi ng the oil filter x ...................... ........... 144 17.5 Cleanin g the oil screens x ............................... 146 17.6 Installin g the oil filter x .................................. 148 17.7 Filling up with engine oil x ..............[...]

1 MEANS OF REPRESEN TATION 7 1.1 Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). All work marked with this symbol requires specialist knowledge and technic al understanding. In the interest of yo[...]

2 SAFETY ADVICE 8 2.1 Use defi nition - intended use KTM sport motorcycles are designed and constructe d 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. 2.2 Safety a dvice A number of safety instructions [...]

2 SAFETY ADVICE 9 2.3 Degrees of risk and symbols Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measur es are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Identifies a danger t[...]

2 SAFETY ADVICE 10 1 Remov al or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases . 2 Remov al or puncturing of parts of the intake system. 3 Lack of proper maintena nce. 4 Replac ing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified [...]

2 SAFETY ADVICE 11 2.6 Protective clothing Warning Risk of injury   Missing or poor protective clothing present s an increased safety risk. – Wear protective clothing (helmet, boots, glove s, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requireme[...]

2 SAFETY ADVICE 12 2.9 Owner's M anual It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains use- ful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to customize the vehicle ideally for y[...]

3 IMPORTA NT INFORMATIO N 13 3.1 Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM de aler.net ; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resultin[...]

3 IMPORTA NT INFORMATIO N 14 Use of the vehicle under difficult conditions, such in rain, high heat or with a heavy load, can lead to considerably more rapid wear of components such as the drive train, brake system, or suspension compone nts. For this reason, it may be necessary to inspect or replace parts before the next scheduled service. It is i[...]

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4 VIEW OF VEHICLE 16 4.1 View of vehicle, front left side (exa mple) 101971-10[...]

4 VIEW OF VEHICLE 17 1 Hand brake lever ( p. 23) 2 Clutch lever ( p. 23) 3 Handrails ( p. 38) 4 Filler cap 5 Engine number ( p. 21) 6 Shift lever ( p. 39) 7 Side stand ( p. 41) 8 Seat release ( p. 38) 9 Compression damping of the shock absorber ( p. 64) 10 Passenger footrests ( p. 39)[...]

4 VIEW OF VEHICLE 18 4.2 View of vehicle, rear right side (ex ample) 101972-10[...]

4 VIEW OF VEHICLE 19 1 Ignition/steering lock ( p. 27) 2 Fork compression adjustmen t 3 Light switch ( p. 25) 3 Turn signal switch ( p. 25) 3 Horn button ( p. 24) 4 Function buttons ( p. 28) 4 Indicator lamps ( p. 29) 5 Emergency OFF switch ( p. 26) 5 Electric starter button ( p. 26) 6 Throttle grip ( p. 24) 7 Fork rebound adjustment 8 Chassis numb[...]

5 SERIAL NUMBE RS 20 5.1 Chassis number 401945-10 The chassis number  is stamped on the steering head on the right. 5.2 Type lab el 101973-10 The type label  is located on the right side of the frame.[...]

5 SERIAL NUMBE RS 21 5.3 Key num ber 100179-10 The key number  can be found on the KEYCODECARD . Info You need the key number to order a spare key. Keep the KEYCODECARD in a safe place. 5.4 Engine n umber 401949-10 The engine number  is stamped on the left side of the engine under the engine sprocket.[...]

5 SERIAL NUMBE RS 22 5.5 Fork par t numbe r 401947-10 The fork part number  is stamped on the inner side of the fork stub. 5.6 Shock a bsorber part number 402025-10 The shock absorber part number  is on the left of the shock absorber.[...]

6 CONTROL S 23 6.1 Clutch lever B01943-10 The clutch lever  is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusti ng. 6.2 Hand brake lever B01944-10 The hand break lever  is fitted on the right side of the handlebar. The hand brake lever operates the front brake.[...]

6 CONTROL S 24 6.3 Throttle grip B01945-10 The throttle grip  is fitted on the right side of the handlebar. 6.4 Horn button B01946-10 The horn button  is fitted on the left side of the handlebar. Possible states • Horn button in neutral position • Horn button pressed – The horn is operated in this position.[...]

6 CONTROL S 25 6.5 Light switch B01946-11 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. 6.[...]

6 CONTROL S 26 6.7 Emergency OFF switch B01947-10 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 – This position is necessary for operat[...]

6 CONTROL S 27 6.9 Ignition/steerin g lock 600825-01 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. Ignition ON – In this position, the ignition [...]

6 CONTROL S 28 6.10.2 Function buttons 401426-10 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 . Button [...]

6 CONTROL S 29 6.10.4 Indicator lamps 401428-01 The indicator lamps offer additional informatio n about the operating state of the motorcy- cle. Possible states The turn signal indicator lamp flashes green simultaneous ly with the turn signal – The turn signal is switched on. The idle speed indicator lamp lights up green – The transmission is s[...]

6 CONTROL S 30 6.10.5 Display 400836-01 When you switch on the ignition, all display segments light up for a second as a function test. 400881-01 LEnGth Following the display function test, the LEnGth wheel circumfere nce is shown for one sec- ond. Info 1870 mm corresponds to the circumference of the 17" front wheel with a series pro- duction [...]

6 CONTROL S 31 6.10.6 Speed display 401443-10 The speed  is shown in kilometers per hour km/h or in miles per hour mph . 6.10.7 Setting kilometers or miles Info If you change the unit, the value ODO is retained and converted accordingly. Making the setting according to the country. Condition The motorcycle is stationary.[...]

6 CONTROL S 32 401444-01 – Switch on the ignition by turning the ignition key to position ON . – Press the MODE button repeatedly until the ODO mode is active. – Keep the MODE button pressed until the display mode changes from km/h to mph or from mph to km/h . 6.10.8 Time 401443-11 The time is shown in area  of the display. Info After reco[...]

6 CONTROL S 33 401444-01 – 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. – Press the MODE button to set the hour. – Press the SET button to set the minut[...]

6 CONTROL S 34 401445-01 – 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 . 6.10.12 Setting/resetting displa y TRIP 2 Info The TRIP 2 trip counter is always running and counts up to 999.9 . T[...]

6 CONTROL S 35 6.10.13 TRIP F display 401447-01 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. 6.10.14 GEAr display 401418-01 In display mode GEAr , the gear cu[...]

6 CONTROL S 36 6.10.15 Coolant temperature indicator 700124-01 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 – Up to four bars light up. • Engine w[...]

6 CONTROL S 37 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. 101975-10 – Lift the cover of filler cap  and insert the ignition key. – Turn the ignition key 90° counterclockwise and remove the filler cap. Info Th[...]

6 CONTROL S 38 6.13 Seat release 101977-10 The seat can be released using strap  . 6.14 Handrails 101978-10 The handrails  are used for moving the motorcycle around. When you have a passenger, the passenger can hold on the handrails during the journey.[...]

6 CONTROL S 39 6.15 Passenger footrests 101979-01 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. 6.16 Shift lever 401950-10 The shift lever  is mounted on the left side of the engine[...]

6 CONTROL S 40 401950-11 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 6.17 Foot brake lever 401956-10 Foot brake lever  is located in front of the right footrest. The rear brake is engaged with the foot brake lever.[...]

6 CONTROL S 41 6.18 Side stand 401943-10 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. Possible states • Side stand folded out[...]

7 PREPARIN G FOR USE 42 7.1 Advice on first use Danger Danger of accidents   Danger arising from the rider's judgem ent being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired. Warning Risk of injury   Missing or poor protective clothing present s[...]

7 PREPARIN G FOR USE 43 Warning Danger of accidents   Failure of brake system. – If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take your foot off the foot brake lever when you are not braking. Info When using your vehicle, remember that others may feel disturbed by exce[...]

7 PREPARIN G FOR USE 44 Guideline Maximum engine speed During the first: 1,000 km (620 mi) 6,000 rpm After the first: 1,000 km (620 mi) 7,800 rpm – Avoid fully opening the throttle! 7.3 Loading the vehicle Warning Danger of accidents   Unstabl e handling characteristics. – Do not exceed the maximum permitted weight and axle loads. The overall[...]

7 PREPARIN G FOR USE 45 Warning Danger of accidents   Poor visibility for other road users due to slipped baggage. – If the tail light is covered, you are less visible to traffic behind you, especially in the dark. Check that your baggage is fixed properly at regular intervals. Warning Danger of accidents   Changed hand ling characteristics a[...]

8 RIDING INSTRUC TIONS 46 8.1 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. 142) – Check the brake fluid level of the front brake. ( p. 91) – Check the[...]

8 RIDING INSTRUC TIONS 47 8.2 Starting Danger Danger of poisoning   Exhaust gase s 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 . Caution D[...]

8 RIDING INSTRUC TIONS 48 Info Do not press the electric starter button until the combination instrument func- tion check is finished. When starting, DO NOT open the throttle. If you open the throttle during the start- ing procedure, fuel is not injected by the engine management system and the engine cannot start. Press the starter for a maximum of[...]

8 RIDING INSTRUC TIONS 49 8.3 Starting off – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully . 8.4 Shifting, riding Warning Danger of accidents   Abrupt load alteratio ns can cause the vehicle to get out of control. – Avoid abrupt load alterations and sudden braking action[...]

8 RIDING INSTRUC TIONS 50 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. – New tires have a smooth rolling surfac[...]

8 RIDING INSTRUC TIONS 51 Note Engine failure   Overheating of engine. – If the coolant temperature warning lamp lights up, stop and switch off the engine. Allow the engine to cool down and check the coolant level in the radiator, and top up if necessary. If you continue with the coolant temperature warning lamp alight, you may have engine fail[...]

8 RIDING INSTRUC TIONS 52 – If the engine stalls (e.g. at a crossroads), just pull the clutch lever and press the elec- tric starter button. You do not have to shift into neutral. – Switch off the engine if you expect to be standing for a long time. – Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and [...]

8 RIDING INSTRUC TIONS 53 Warning Danger of accidents   Longer stoppi ng distance due to higher overall weight. – Take the longer stopping distance into account when carrying a passenger and baggag e. Warning Danger of accidents   Delayed brake actio n on salted roads. – There may be salt deposits on the brake discs. In order to restore the[...]

8 RIDING INSTRUC TIONS 54 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. – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. ?[...]

8 RIDING INSTRUC TIONS 55 Note Material damage   Damage to or destruction of components due to excessive load. – The side stand is only designed for the weight of the motorcycle. Do no sit on the motorcycle when it is resting on the side stand. The side stand or the frame may become damaged and the motorcycle may fall over. – Brake the motorc[...]

8 RIDING INSTRUC TIONS 56 Note Fire ha zard   Some vehicle compon ents 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. Always let the vehicle cool first. 401448-01 – Switch off the engine and remove the ig[...]

8 RIDING INSTRUC TIONS 57 Note Material damage   Premature clogging of the fuel filter. – 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 specifie[...]

8 RIDING INSTRUC TIONS 58 401429-10 – 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. three minutes.[...]

9 SERVICE SCHED ULE 59 9.1 Service schedule Every 20,000 km (12,428 mi) or every 2 years Every 10,000 km (6,214 mi) o r annua lly or after every sporting use Once after 1,000 km (621.4 m i) Check that the electrical equipment is functioning correctl y. ○ ● ● Read out the fault memory using the KTM diagnostics tool. x ○ ● ● Check the mea[...]

9 SERVICE SCHED ULE 60 Every 20,000 km (12,428 mi) or every 2 years Every 10,000 km (6,214 mi) o r annua lly or after every sporting use Once after 1,000 km (621.4 m i) Grease all moving parts (e.g. side stand, hand lever, chain, ...) and check for smooth operation. x ○ ● ● Clean the dust boots of the fork legs. ( p. 72) ● ● Check the bra[...]

9 SERVICE SCHED ULE 61 Every 20,000 km (12,428 mi) or every 2 years Every 10,000 km (6,214 mi) o r annua lly or after every sporting use Once after 1,000 km (621.4 m i) Check the headlight setting. ( p. 130) ○ ● ● Check that the radiator fan is functioning properly. x ○ ● ● Final check: Check the vehicle for roadworthiness and take a te[...]

10 TUNING THE CHASSIS 62 10.1 Fork/shock absorber 101980-10 The fork and the shock absorber offer many options of adapting the chassis to your riding style and the payload. Info To help you adapt the vehicle, we have summarized our findings in Table  . You can find the table on the underside of the seat. These adjustments should be understoo d a[...]

10 TUNING THE CHASSIS 63 Guideline Compression damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping; turn counterclo ckwise to reduce damping. 10.3 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determin es the fork rebound behavior. 101982-10 – T[...]

10 TUNING THE CHASSIS 64 Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping; turn counterclo ckwise to reduce damping. 10.4 Compression damping of the shock absorber The compression damping of the shock absorber is divided into two ranges: high-spee d and low[...]

10 TUNING THE CHASSIS 65 Info The low-speed setting takes effect during the slow to normal compression of the shock absorber. 101983-10 – Turn adjusting screw  clockwise with a screwdriver up to the last perceptible click. Info Do not loosen fitting  ! – Turn back counterclockwise by the number of clicks correspond ing to the shock absorb[...]

10 TUNING THE CHASSIS 66 Info The high-speed setting takes effect during the fast compression of the shock absorber . 101983-11 – Turn adjusting screw  clockwise all the way using a socket wrench. Info Do not loosen fitting  ! – Turn back counterclockwise by the number of turns correspondin g to the shock absorber type. Guideline Compress[...]

10 TUNING THE CHASSIS 67 601891-10 – Turn adjusting screw  clockwise up to the last perceptible click. – Turn back counterclockwise by the number of clicks correspond ing to the shock absorber type. Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Info Turn clockwise to increase damping; t[...]

10 TUNING THE CHASSIS 68 10.9 Adjusting the handlebar position x 601875-10 – Remove the four screws  . Remove the handlebar clamps. Take off the handlebar and set it aside. Info Cover the motorcycle and attachments to protect them from damage. Do not kink the cables and lines. – Remove the two screws  . Take off the handlebar holder. – [...]

11 SERVICE WORK ON THE CHASSIS 69 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. 401942-01 – Stand the motorcycle upright on a level surface. – Raise the motorcycle in the area of the footrest bracket. – Secure the [...]

11 SERVICE WORK ON THE CHASSIS 70 401943-10 – Remove the motorcycle from the lift stand and rest it on its side stand. – Remove the lift stand. 11.3 Raising the motorcycle with the rear 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. 101984-10 – Inse[...]

11 SERVICE WORK ON THE CHASSIS 71 11.4 Taking the motorcycle off of the rear 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. 401943-10 – Secure the motorcycle against falling over. – Remove the rear wheel stand and lean the vehicle on the side stand. 1[...]

11 SERVICE WORK ON THE CHASSIS 72 101985-01 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. – Raise the front of the motorcycle. 11.6 Taking the motorcycle off of the front wheel s[...]

11 SERVICE WORK ON THE CHASSIS 73 L00350-10 Main work – Push dust boots  on both fork legs downward. Info The dust boots remove dust and coarse dirt particles from the inside fork tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not removed, the oil seals behind the dust boots can start to leak. Warning Danger of acc[...]

11 SERVICE WORK ON THE CHASSIS 74 11.8 Removing the fork protector 101986-10 – 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. 11.9 Installing the fork protector 101986-11 – Position the fork protection on the left fo[...]

11 SERVICE WORK ON THE CHASSIS 75 11.10 Removing the seat 101977-10 – Pull on strap  and raise the rear of the seat at the same time. – Pull back the seat and lift it off. 11.11 Mounting the seat 101988-10 – Hook slot  of the seat onto screw  , press the rear downward and at the same time push it forward. – Push locking pin  int[...]

11 SERVICE WORK ON THE CHASSIS 76 11.12 Removing the air filter x Preparatory work – Remove the seat. ( p. 75) 601882-10 Main work – Remove screws  . Take off air filter box top  . 601880-10 Note Engine failure   Unfiltered intake air has a negative effect on the service life of the engine. – Never operate the vehicle without an air f[...]

11 SERVICE WORK ON THE CHASSIS 77 11.13 Installing the air filter x 601881-10 Main work – Clean the air filter box. – Mount air filter  . Info The air filter must lie flush against the air filter box along the entire sealing sur- face  . If the air filter is not correctly mounted, dust and dirt can enter the engine and cause damage. – H[...]

11 SERVICE WORK ON THE CHASSIS 78 11.14 Checking the chain for dirt 400678-01 – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 78) 11.15 Cleaning the chain Warning Danger of accidents   Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning[...]

11 SERVICE WORK ON THE CHASSIS 79 Info The service life of the chain depends largely on its maintenance. 400725-01 – Clean the chain regularly. – Rinse off loose dirt with a soft jet of water. – Remove old grease remains with chain cleaner. Chain cleaner ( p. 185) – After drying, apply chain spray. Chain lube for road use ( p. 185) 11.16 Ch[...]

11 SERVICE WORK ON THE CHASSIS 80 100249-10 – 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. Chain wear is not always even. Repeat this measurement at different chain posi[...]

11 SERVICE WORK ON THE CHASSIS 81 11.17 Adjusting the chain tension Warning Danger of accidents   Danger cause d 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. In[...]

11 SERVICE WORK ON THE CHASSIS 82 101989-10 Main work – Loosen nut  . – Loosen nuts  . – Adjust the chain tension by turning adjusting screws  on the left and right. Guideline Chain tension 5 mm (0.2 in) Turn the left and right adjusting screws  so that the markings on the left and right chain adjusters  are in the same positio[...]

11 SERVICE WORK ON THE CHASSIS 83 100132-10 Main work – Shift the transmission to neutral. – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket and engine sprocket are worn: – Change the power set. x Info The engine sprocket, rear sprocket, and chain should always be replaced together. 1 2 3 1 6 1 7 1 8 0 0 0 B B 0 [...]

11 SERVICE WORK ON THE CHASSIS 84 401170-01 – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with or below the chain sliding guard: – Replace the chain sliding guard. x – Check that the chain sliding guard is firmly seated. » If the chain sliding guard is loose: – Tighten the chain sliding guard. [...]

11 SERVICE WORK ON THE CHASSIS 85 401171-01 – 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. x – Check that the chain sliding piece is firmly seated. » If the chain sliding piece is loose: – Tighten the chain sliding piece. G[...]

11 SERVICE WORK ON THE CHASSIS 86 601884-01 – Check that the chain guide is firmly seated. » If the chain guide is loose: – Tighten the chain guide. Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) Finishing work – Take the motorcycle off of the rear wheel stand. ( p. 71) 11.19 Adjusting basic position of clutch lever Info Turn the [...]

11 SERVICE WORK ON THE CHASSIS 87 102009-10 – Adjust the basic setting 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) 11.20 Checking/re ctifying the fluid level of the hydraul[...]

12 BRAKE SYSTEM 88 12.1 ABS/antilock brake system 402028-10 The ABS unit  , which consists of a hydraulic unit, ABS control unit, and return pump, is installed under the seat. A wheel speed sensor  is located at the front and rear wheels. Warning Danger of accidents   Function al limitations of the ABS – The rear wheel may only be spun wi[...]

12 BRAKE SYSTEM 89 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. In this case, the ABS is no longer enabled and the wheels may lock during braking. The brake system itself stays [...]

12 BRAKE SYSTEM 90 12.3 Checking the brake discs Warning Danger of accidents   Reduced brak ing efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) 100135-10 – Check the thickness of the front and rear brake discs in several places to ensure that it conforms[...]

12 BRAKE SYSTEM 91 12.4 Checking brake fluid level of front brake Warning Danger of accidents   Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to[...]

12 BRAKE SYSTEM 92 Warning Skin irr itation   Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles . – If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediate[...]

12 BRAKE SYSTEM 93 102011-10 – Remove screws  . – Remove cover  with membrane  . – Add brake fluid to level  . Guideline Measurement of  5 mm (0.2 in) Brake fluid DOT 4 / DOT 5.1 ( p. 181) – Position the cover with the membrane. Mount and tighten the screws. Info Clean up overflowed or spilt brake fluid immediately with water[...]

12 BRAKE SYSTEM 94 101990-10 – Check the brake linings for minimum thickness  . Minimum thickness  ≥ 1 mm ( ≥ 0.04 in) » If the minimum thickness is less than specified: – Change the brake linings of the front brake. x – Check the brake linings for damage and cracking. » If there is wear or tearing: – Change the brake linings of[...]

12 BRAKE SYSTEM 95 12.8 Adjusting the basic position of the foot brake lever x Warning Danger of accidents   Brake system failur e. – 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. Adjust the free travel on foot brake lever according to specificatio[...]

12 BRAKE SYSTEM 96 12.9 Checking rear brake fluid level Warning Danger of accidents   Failure of the brake system. – If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Wa[...]

12 BRAKE SYSTEM 97 Warning Skin irr itation   Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – Wear suitable protective clothing and goggles . – If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediate[...]

12 BRAKE SYSTEM 98 101993-10 Main work – Stand the vehicle upright. – Remove screw cap  with the washer and membrane  . – Add brake fluid to the MAX mark. Brake fluid DOT 4 / DOT 5.1 ( p. 181) – Mount the screw cap with the washer and membrane. Info Clean up overflowed or spilt brake fluid immediately with water. 12.11 Checking the re[...]

12 BRAKE SYSTEM 99 101994-10 – Check the brake linings for minimum thickness  . Minimum thickness  ≥ 1 mm ( ≥ 0.04 in) » If the minimum thickness is less than specified: – Change the rear brake linings. x – Check the brake linings for damage and cracking. » If there is wear or tearing: – Change the rear brake linings. x[...]

13 WHEELS, TIRES 100 13.1 Removing front wheel x Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 70) – Raise the motorcycle with the front wheel stand. ( p. 71) 101995-10 Main work – Remove screw  and pull wheel speed sensor  out of the hole. – Remove screws  and spacers  . – Press back the brake lining[...]

13 WHEELS, TIRES 101 101998-10 – Remove spacers  . 13.2 Installing the front wheel x Warning Danger of accidents   Reduced brak ing 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. 101998-11 Main work – Check the wheel bearing for d[...]

13 WHEELS, TIRES 102 101997-10 – Clean and grease the thread of the wheel spindle and screw  . Long-life grease ( p. 185) – 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) – Insert wheel speed sensor  into the ho[...]

13 WHEELS, TIRES 103 101999-10 – Take the motorcycle off of the front wheel stand. ( p. 72) – Pull the front wheel brake and push down hard on the fork several times to align the fork legs. – Tighten screws  . Guideline Screw, fork stub M8 15 Nm (11.1 lbf ft) Finishing work – Take the motorcycle off of the rear wheel stand. ( p. 71) 13.3[...]

13 WHEELS, TIRES 104 102001-01 – Pull out wheel spindle  to the point where the chain adjuster is no longer in contact with the adjusting screw. – Push the rear wheel forwards as far as possible and take the chain off the rear sprocket. – Pull out the wheel spindle. Warning Danger of accidents   Reduced brak ing effect caused by damaged [...]

13 WHEELS, TIRES 105 102002-10 – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Replace the wheel bearing. x – Remove bushing  . Clean and grease the roll surfaces of the bushing and the shaft seal ring  . Long-life grease ( p. 185) – Mount the bushing. – Clean and grease the threads of th[...]

13 WHEELS, TIRES 106 102003-10 – Push the rear wheel forward as far as possible and lay the chain on the rear sprocket. – Mount the wheel spindle, chain adjuster  , and nut  . Guideline In order for the rear wheel to be correctly aligned, the markings on the left and right chain adjusters must be in the same position relative to the refer[...]

13 WHEELS, TIRES 107 Preparatory work – Raise the motorcycle with the rear wheel stand. ( p. 70) – Remove the rear wheel. x ( p. 103) 102004-10 Main work – Check bearing  . » If the bearing is damaged or worn: – Replace the bearings. x – Check rubber dampers  of the rear hub for damage and wear. » If the rubber dampers of the rear[...]

13 WHEELS, TIRES 108 13.6 Checking the tire condition Warning Danger of accidents   Uncontr ollable vehicle handling in the event of a flat tire. – In the interest of safety, replace damaged or worn tires immediately. (Your authorized KTM worksho p will be glad to help.) Warning Danger of crashing   Poor vehicle handlin g due to different tir[...]

13 WHEELS, TIRES 109 400602-10 – Check the front and rear tires for cuts, run-in objects and other damage. » If the tires exhibit cuts, run-in objects or other damage: – Change the tires. – Check the depth of the tread. Info Note local national regulations concerni ng the minimum tread depth. Minimum tread depth ≥ 2 mm ( ≥ 0.08 in) » If[...]

13 WHEELS, TIRES 110 13.7 Tubeless tire system 301978-10 This vehicle makes use a tubeless tire system in which a tubeless sealing profile  is used instead of the conventional tube. The advantages of the tubeless system lie in the absence of danger from a faulty tube. This greatly reduces the risk of a sudden loss in pressure. The masses and mom[...]

13 WHEELS, TIRES 111 400695-01 – Remove the protection cap. – Check tire air pressure when tires are cold. 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) » If the tire pressure does not meet specifications: – Correct tire pressu[...]

13 WHEELS, TIRES 112 400694-01 – 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. You should hear a high note. »[...]

14 ELECTRIC AL SYSTEM 113 14.1 Removing the battery x Warning Risk of injury   Battery acid and battery gases cause serious chemica l burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles . – Avoid contact with battery acid and battery gases. – Keep sparks and open flames away from the batte[...]

14 ELECTRIC AL SYSTEM 114 B01975-10 – Disconnect negative cable  of the battery. – Take off the positive terminal cover  and disconnect the positive cable from the bat- tery. – Remove screws  . – Pull retaining bracket  of the battery forward and remove it. – Lift the battery up and out. Info Never operate the motorcycle with [...]

14 ELECTRIC AL SYSTEM 115 Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) B01976-10 – Position EFI control unit  . – Mount battery cover  . Finishing work – Mount the seat. ( p. 75) – Set the clock. ( p. 32) 14.3 Recharging the battery x Warning Risk of injury   Battery acid and battery gases cause serious chemica l burns.[...]

14 ELECTRIC AL SYSTEM 116 Warning Environmental hazard   The battery contains elements that are harmful to the environment. – Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentall y compatible manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batt[...]

14 ELECTRIC AL SYSTEM 117 100151-10 Main work – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000 ) You can also use the battery charger to test rest potential and start potential of the bat- tery, and to test the alternator. With this device, you cannot overcharge the battery. Info Never remo[...]

14 ELECTRIC AL SYSTEM 118 14.4 Changing the main fuse Warning Fire ha zard   The electrical system can be overloade d if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers in the vehicle. It is in the housing of the starter relay next to the bat[...]

14 ELECTRIC AL SYSTEM 119 102007-10 – 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. 173) Info Insert a new replacement fuse into the starter relay to have it availa[...]

14 ELECTRIC AL SYSTEM 120 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. B01979-10 To cha nge th e fuse of the ABS hydraulic unit: – Take off protection cap  and remove the fuse. ?[...]

14 ELECTRIC AL SYSTEM 121 14.6 Changing 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. ( p. 75) 102012-10 Main work – Open fuse box cover  .[...]

14 ELECTRIC AL SYSTEM 122 102008-10 – Remove the defective fuse. Guideline Fuse 1 - 10 A - ignition, combination instrumen t, clock, EFI control unit Fuse 2 - 10 A - ignition, combination instrumen t, 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, l[...]

14 ELECTRIC AL SYSTEM 123 Tip Put a new spare fuse in the fuse box for future use if needed. – Check the function of power consumers. – Close the fuse box cover. Finishing work – Mount the seat. ( p. 75) 14.7 Removing the headlight mask with the headlight Preparatory work – Switch off all power consumers and switch off the engine. 102025-10[...]

14 ELECTRIC AL SYSTEM 124 102026-10 – Disconnect the connectors of turn signals  and headlight  . – Remove the headlight mask. 14.8 Installing the headlight mask with the headlight 102026-11 Main work – Connect the connectors of headlight  and turn signal lights  . – Check lighting function.[...]

14 ELECTRIC AL SYSTEM 125 102027-10 – Remove the cloth from the fender and position the headlight mask. Holding lugs  reach into the headlight mask. 102028-10 – Position groove  on counterpiece  . 102025-11 – Position brake line guides  . Mount and tighten screws  . Guideline Screw, headlight mask M5 5 Nm (3.7 lbf ft)[...]

14 ELECTRIC AL SYSTEM 126 Finishing work – Check the headlight setting. ( p. 130) 14.9 Changing the headlight bulb Note Damage to reflector   Reduced brigh tness. – 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. Preparatory work – Switch off all[...]

14 ELECTRIC AL SYSTEM 127 600611-10 – Detach spring bar  . – Remove headlight bulb  . – Insert a new headlight bulb into the headlight housing. Headlight (H4 / socket P43t) ( p. 174) – Fix the headlight bulb in the headlight using the spring bar. – Mount the protection cap. Attach the connector. Finishing work – Install the headli[...]

14 ELECTRIC AL SYSTEM 128 600610-12 Main work – Remove protection cap  . 600612-10 – Pull bulb socket  out of the reflector. – Pull parking light bulb  out of the bulb socket. – Insert a new parking light bulb in the bulb socket. Parking light (W5W / socket W2.1x9.5d) ( p. 174) – Insert the bulb socket in the reflector. – Inser[...]

14 ELECTRIC AL SYSTEM 129 14.11 Changing the turn signal bulb Note Damage to reflector   Reduced brigh tness. – 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. 100160-10 Main work – Remove the screw on the rear of the turn signal housing. – Caref[...]

14 ELECTRIC AL SYSTEM 130 14.12 Checking the headlight setting 400726-10 – 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. Guideline Distance  5 cm (2 in) – Position the vehicle verti[...]

14 ELECTRIC AL SYSTEM 131 102024-10 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). Info Turn clockwise to increase the headlight range; turn[...]

15 COOLING SYSTE M 132 15.1 Cooling system 102013-10 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  . When the temperature falls, this surplus c[...]

15 COOLING SYSTE M 133 Warning Danger of poisoning   Coolant is poisonou s 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 contam inated areas on the skin with soap and water. If coolant is swall[...]

15 COOLING SYSTE M 134 102015-10 – 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. » If th[...]

15 COOLING SYSTE M 135 Warning Danger of poisoning   Coolant is poisonou s 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 contam inated areas on the skin with soap and water. If coolant is swall[...]

15 COOLING SYSTE M 136 Alternative 2 Coolant (mixed ready to use) ( p. 181) – Mount the radiator cap. 15.4 Draining the coolant x Warning Danger of scalding   During motorcy cle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot[...]

15 COOLING SYSTE M 137 15.5 Filling/bleedin g the cooling system x Warning Danger of poisoning   Coolant is poisonou s 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 contam inated areas on the s[...]

15 COOLING SYSTE M 138 102018-10 – Remove the cap from compensating tank  and add coolant to the level shown in the figure. – Mount the cap of the compensating tank. Danger Danger of poisoning   Exhaust gase s are toxic and inhaling them may result in unconsciousness and/o r death. – When running the engine, always make sure there is suf[...]

16 TUNING THE ENGINE 139 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) 102019-10 Main work – Pull the Map ‑ Select switch and holder  upward off of the retaining bracket. – Pull the Map ‑ Select switch out of the holder. 60[...]

16 TUNING THE ENGINE 140 – 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 0 0 0 A A 400692-10 – Sit on the vehicle in the riding position and determine distan[...]

16 TUNING THE ENGINE 141 401951-10 – Clean gear teeth  of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure. – Mount and [...]

17 SERVICE WORK ON THE ENGINE 142 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. C00182-10 Main work – Check the engine oil level. Info After switching off the engine, [...]

17 SERVICE WORK ON THE ENGINE 143 17.2 Changing the engine oil and filter, cleaning the oil screens x 601022-10 – Drain the engine oil. x ( p. 143) – Remove the oil filter. x ( p. 144) – Clean the oil screens. x ( p. 146) – Install the oil filter. x ( p. 148) – Fill up with engine oil. x ( p. 148) 17.3 Draining the engine oil x Warning Da[...]

17 SERVICE WORK ON THE ENGINE 144 100200-10 – Place a suitable container under the engine. – Remove the oil drain plug  with the magnet and seal ring. – Completely drain the engine oil. 100201-01 – Thoroughly clean the oil drain plug with a magnet. – Mount the oil drain plug with the magnet and seal ring and tighten it. Guideline Oil d[...]

17 SERVICE WORK ON THE ENGINE 145 Warning Environmental hazard   Hazardous substances caus e environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulatio ns. Preparatory work – Place a suitable container under the engine. 102020-10 Main work – Remove screws  [...]

17 SERVICE WORK ON THE ENGINE 146 17.5 Cleaning the oil screens x Warning Danger of scalding   Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothin g and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard   Hazardous substances caus e enviro[...]

17 SERVICE WORK ON THE ENGINE 147 100206-10 – Remove screw plug  with oil screen  and the O-rings. – Completely drain the remaining engine oil. – Thoroughly clean the parts and sealing area. 100207-10 – Position oil screen  with the O-rings. – Mount and tighten screw plug  with the O-ring. Guideline Plug, oil screen M20x1.5 15[...]

17 SERVICE WORK ON THE ENGINE 148 17.6 Installing the oil filter x 102022-10 – Insert oil filters  and  . – Oil the O-rings of the oil filter covers. Mount oil filter covers  and  . – Mount and tighten the screws. Guideline Screw, oil filter cover M5x16 6 Nm (4.4 lbf ft) 17.7 Filling up with engine oil x Info Too little engine oil[...]

17 SERVICE WORK ON THE ENGINE 149 Danger Danger of poisoning   Exhaust gase s are toxic and inhaling them may result in unconsciousness and/o r 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. – Start the [...]

17 SERVICE WORK ON THE ENGINE 150 Danger Danger of poisoning   Exhaust gase s are toxic and inhaling them may result in unconsciousness and/o r 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. – Start the [...]

18 CLEANING , CARE 151 18.1 Cleaning the motorcycle Note Material damage   Damage and destruction of components by high-pressur e cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connec tors, cables, bearings, etc. Maintain a minimum distance of 60 cm betwee[...]

18 CLEANING , CARE 152 – 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 brak ing efficiency due to a wet or dirty brake sys- tem. – Clean or dry a dirty or wet brake system by riding and braking gently. – After cleaning[...]

18 CLEANING , CARE 153 Special cleaner for glossy and matte paint finishes, metal and plastic surfaces ( p. 186) – Lubricate the ignition/steering lock. Universal oil spray ( p. 186) 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 precaut[...]

18 CLEANING , CARE 154 – Clean the chain. ( p. 78)[...]

19 STORAGE 155 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. Immedia tely clean contaminated areas on the skin with soap[...]

19 STORAGE 156 – Recharge the battery. x ( p. 115) Guideline Storage temperature of battery without direct sunshine 0… 35 °C (32… 95 °F) – 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. 7[...]

19 STORAGE 157 19.2 Preparing for use after storage 401059-01 – Take the motorcycle off of the front wheel stand. ( p. 72) – Take the motorcycle off of the rear wheel stand. ( p. 71) – Recharge the battery. x ( p. 115) – Install the battery. x ( p. 114) – Set the clock. ( p. 32) – Perform checks and vehicle care when preparing for use. [...]

20 TROUBLE SHOOTING 158 Faults Possible cause Actio n The engine does not turn when the starter button is pressed Operating error – Carry out the start procedure. ( p. 47) Battery is discharged – Recharge the battery. x ( p. 115) Fuse 1 or 2 blown – Change the fuses of individual power consumers. ( p. 121) – Set the clock. ( p. 32) Main fus[...]

20 TROUBLE SHOOTING 159 Faults Possible cause Actio n Engine overheats. Foam formation in cooling system – Drain the coolant. x ( p. 136) – Fill/bleed the cooling system. x ( p. 137) Buckled or damaged radiator hose – Change the radiator hose. x Thermostat is faulty – Check the thermostat. x Fuse 5 blown – Cha nge the fuses of individual [...]

20 TROUBLE SHOOTING 160 Faults Possible cause Actio n Turn signal, brake light and horn not functioning Fuse 5 blown – Cha nge the fuses of individual power consumers. ( p. 121) Time is not (correctly) displayed Fuse 1 blown – Cha nge the fuses of individual power consumers. ( p. 121) – Set the clock. ( p. 32) Battery discharged Ignition not [...]

21 BLINK CODE 161 Blink code FI of warning lamp (MIL) 02 FI warning lamp ( MIL ) flashes briefly 2x Error le vel co ndition Crankshaft position sensor - circuit fault Blink code FI of warning lamp (MIL) 09 FI warning lamp ( MIL ) flashes briefly 9x Error le vel co ndition Manifold absolute pressure sensor cylin der 1 - input signal too low Manifold[...]

21 BLINK CODE 162 Blink code FI of warning lamp (MIL) 15 FI warning lamp ( MIL ) flashes 1x long, 5x short Error le vel co ndition 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 le vel co ndition Lambda sensor cylinder 1, s[...]

21 BLINK CODE 163 Blink code FI of warning lamp (MIL) 27 FI warning lamp ( MIL ) flashes 2x long, 7x short Error le vel co ndition Accelerator position sensor circuit fault - accelerator posit ion sensor voltage Blink code FI of warning lamp (MIL) 33 FI warning lamp ( MIL ) flashes 3x long, 3x short Error le vel co ndition Injector cylinder 1 - cir[...]

21 BLINK CODE 164 Blink code FI of warning lamp (MIL) 45 FI warning lamp ( MIL ) flashes 4x long, 5x short Error le vel co ndition 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 ) flashe[...]

21 BLINK CODE 165 Blink code FI of warning lamp (MIL) 85 FI warning lamp ( MIL ) flashes 8x long, 5x short Error le vel co ndition 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 Error l[...]

21 BLINK CODE 166 Blink code FI of warning lamp (MIL) 92 FI warning lamp ( MIL ) flashes 9x long, 2x short Error le vel co ndition 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 le vel co ndition CPU mutual - surveillance error Blink code FI of warning lam[...]

22 TECHNICA L DATA 167 22.1 Engine Design 1-cylinder 4-stroke engine, water-co oled 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, int[...]

22 TECHNICA L DATA 168 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 electro nic 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 0.9 mm[...]

22 TECHNICA L DATA 169 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 M5 6 Nm (4.4 lbf ft) Loctite ® 243™ Cylinder head screw M6x25 10 Nm (7.4 lbf ft) Loctite ® 243™ Plug, vacuum connection M6 10 Nm (7.4 lbf ft) Loctite ® 243™ Remaining sc[...]

22 TECHNICA L DATA 170 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 ® 243™ Screw, timing chain tensioning rail M6x30 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, valve cover M6 10 Nm (7.4 lbf ft) – Screw, water pump cover M6x30 10 Nm (7.4 lbf ft) – Screw, wat[...]

22 TECHNICA L DATA 171 Screw, unlocking of timing chain ten- sioner M10x1 10 Nm (7.4 lbf ft) – 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 head M12x1.5 12 Nm (8.9 lbf ft) – Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) – Oil pressure regulat[...]

22 TECHNICA L DATA 172 22.3.2 Coolant Coolant 1.20 l (1.27 qt.) Coolant ( p. 181) Coolant (mixed ready to use) ( p. 181) 22.3.3 Fuel Total fuel tank capacity, approx. 12 l (3.2 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 183) Fuel reserve, approx. 2.5 l (2.6 qt.) 22.4 Chassis Frame Lattice frame made of chrome molybdenum steel tubing, powde [...]

22 TECHNICA L DATA 173 Front 4.0 mm (0.157 in) 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” X ‑ ring Steering head angle 63° Wheelbase 1,480±15 mm (58.27±0.59[...]

22 TECHNICA L DATA 174 Fuse 75011088015 15 A Fuse 75011088010 10 A Headlight H4 / socket P43t 12 V 60/55 W Parking light W5W / socket W2.1x9.5d 12 V 5 W Instrument lights and indicator lamps LED Turn signal RY10W / socket BAU15s 12 V 10 W Brake/tail light LED License plate lamp W5W / socket W2.1x9.5d 12 V 5 W 22.6 Tires Front tires Rear tir es 120/[...]

22 TECHNICA L DATA 175 Standard 15 clicks Sport 10 clicks Full payload 10 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 10 clicks Full payload 10 clicks Spring length with preload spacer(s) 463 mm (18.23 in) Spring rate Medium (standard) 5.3 N/mm (30.3 lb/in) Air chamber length 110 +20 − 30 mm (4.33 +0.79 − 1.18 in) Fork len[...]

22 TECHNICA L DATA 176 Comfort 25 clicks 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 220 mm (8.66 in) Gas pressure 10 [...]

22 TECHNICA L DATA 177 Screw, side cover on spoiler EJ OT 1 Nm (0.7 lbf ft) – Screw, side stand switch EJOT 2 Nm (1.5 lbf ft) – Screw, SLS valve EJ OT 2 Nm (1.5 lbf ft) – Fitting, side stand switch M4 2 Nm (1.5 lbf ft) – Spoke nipple, front wheel M4.5 3… 6 Nm (2.2… 4.4 lbf ft) – Spoke nipple, rear wheel M4.5 3… 6 Nm (2.2… 4.4 lbf [...]

22 TECHNICA L DATA 178 Screw, air filter box top M6 2 Nm (1.5 lbf ft) – Screw, ball joint of push rod on foot brake cylinder M6 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, brake fluid reservoir of rear brake M6 5 Nm (3.7 lbf ft) – Screw, chain guard M6 2 Nm (1.5 lbf ft) Loctite ® 243™ Screw, chain guide M6 8 Nm (5.9 lbf ft) – Screw, chain [...]

22 TECHNICA L DATA 179 Screw, foot brake lever M8 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, fork stub M8 15 Nm (11.1 lbf ft) – Screw, front footrest bracket M8 25 Nm (18.4 lbf ft) – Screw, fuel tank bracket M8 15 Nm (11.1 lbf ft) – Screw, fuel tank, bottom M8 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, fuel tank, top M8 25 Nm (18.4 lbf ft[...]

22 TECHNICA L DATA 180 Screw, side stand M10 35 Nm (25.8 lbf ft) Loctite ® 243™ Screw, top shock absorber M10 45 Nm (33.2 lbf ft) Loctite ® 243™ Banjo bolt, brake line M10x1 20 Nm (14.8 lbf ft) – Screw, front brake caliper M10x1.25 45 Nm (33.2 lbf ft) Loctite ® 243™ Screw, swingarm pivot M12 80 Nm (59 lbf ft) – Lambda sensor M12x1.25 2[...]

23 SUBSTAN CES 181 Brake fluid DOT 4 / DOT 5.1 Standard/classific ation – DOT Guideline – Use only brake fluid that complies with the specified standard (see specification s on the container) and that possesses the correspond- ing properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ® – Brake Fluid DOT 5. 1 C[...]

23 SUBSTAN CES 182 Engine oil (SAE 10W/60) (00062010035) Standard/classific ation – JASO T903 MA ( p. 187) – SAE ( p. 187) (SAE 10W/60) – KTM LC4 2007+ Guideline – Use only engine oils that comply with the specified standards (see specification s on the container) and that possess the corresponding properties. Synthetic engine oil Recommend[...]

23 SUBSTAN CES 183 Fork oil (SAE 4) (48601166S1) Standard/classific ation – SAE ( p. 187) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corres ponding proper- ties. Hydraulic fluid (15) Standard/classific ation – ISO VG (15) Guideline – Use only hydrauli[...]

23 SUBSTAN CES 184 Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).[...]

24 AUXILIAR Y SUBSTANCES 185 Chain cleaner Recommended supplier Motorex ® – Chain Clean Chain lube for road use Guideline Recommended supplier Motorex ® – Chainlube Road Fuel additive Recommended supplier Motorex ® – Fuel St abilizer Long-life grease Recommended supplier Motorex ® – Bike Gr ease 2000 Motorcycle cleaner Recommended suppl[...]

24 AUXILIAR Y SUBSTANCES 186 Perfect Finish and high gloss polish for paints Recommended supplier Motorex ® – Moto Polish & Shi ne 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 ® ?[...]

25 STANDAR DS 187 JASO T903 MA Different technical developme nt directions required a new specification for 4-stroke motorcyc les – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles becau se there was no separate motorcycle specification. Whereas long service intervals are demanded f[...]

INDEX 188 INDEX A ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Air filte r installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 removing . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

INDEX 189 Combination instrument clock, setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 coolant temperature indicator . . . . . . . . . . . . . . . . . . . . . 36 display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 function buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

INDEX 190 Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 compression damping, adjus ting . . . . . . . . . . . . . . . . . . . 62 dust boots, cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 rebound, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Fork pa rt num ber . . [...]

INDEX 191 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Oil scre ens cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143, 146 Operating substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 O[...]

INDEX 192 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 T Technical data capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

*32131 04en* 3213104en 12/2013 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com Photo: Mitterbauer/KTM[...]